OPERATION MANUAL

PB-GL SERIES HYDRAULIC PRESS BRAKE

E21 CONTROLLER

Models
S970GL, S902GL, S906GL, S908GL, S909GL, S910GL, S912GL

Edition No : PB-GL 004

Date of Issue : 01/2024
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MACHINE DETAILS

MACHINE HYDRAULIC PRESS BRAKE

MODEL NO.

SERIAL NO.

DATE OF MANF.

Distributed by

www.machineryhouse.co.nz

Note:
This manual is only for your reference. Owing to the continuous improvement of the
Metalmaster machine, changes may be made at any time without obligation or notice.
Please ensure the local voltage is the same as listed on the specification plate before
operating any electric machine.

NOTE:
In order to see the type and model of the machine, please see the
specification plate. Usually found on the back of the machine. See
example (Fig.1)
Fig.1

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C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1.1 Specifications............................................................... 5
1.2 Standard Equipment................................................. 6
1.3 Identification................................................................ 7

2. IMPORTANT INFORMATION
2.1 General Metalworking Machine Safety.............. 8
2.2 Specific Safety for Press Brake Machines........... 11
2.3 Lifting Instructions..................................................... 13

3. INSTALLATION
3.1 Site Selection and Preparation.............................. 14
3.2 Machine Leveling....................................................... 15
3.3 Electrical Installation................................................. 15
3.4 Full Load Current........................................................ 16
3.5 Checking The Power Supply................................... 16
3.6 Attaching The Accessories...................................... 17

4. COMMISSIONING
4.1 Press Brake Guarding - Laser Guarding ............. 18
4.2 Laser Guarding Safety Controller ........................ 19
4.3 Laser Safety Controller - Layout ........................... 20
4.4 Laser Safety Controller - Operating modes....... 21
4.5 Laser Setup & Calibration - Magnet Type Calibrator ..... 22
4.6 Stopping test - Magnet Type Calibrator ............................. 23
4.7 Laser Safety Periodical check ................................ 25
4.8 Controls.......................................................................... 26

5. OPERATION
5.1 Starting The Machine For The First Time............ 27
5.2 Testing The Emergency Stops................................ 28
5.3 Setting The Height Stops......................................... 28
5.4 Estun E21 Controller Operation............................ 29
5.5 PB-135E E21 Press Brake Calibration: X Axis..... 31
PB-135E E21 Press Brake Calibration: Y Axis...... 32
5.6 Removing & Replacing Tools.................................. 33
5.7 Aligning The Punch And Die................................... 34
5.8 Adjusting The Backgauge........................................ 34
5.9 Bending Techniques.................................................. 35
5.10 Tonnage Chart .......................................................... 36
5.11 Adjusting The Tonnage........................................... 37
5.12 Top Tool Holder Wedge Adjustment.................. 37

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6. MAINTENANCE
6.1 Maintaining Hydraulic System............................... 38
6.2 Lubrication.................................................................... 42
6.3 System error list .......................................................... 43
6.4 General Troubleshooting ....................................... 44
6.5 One Piece 4 Sided Die............................................... 46
6.6 Segmented Top Punch............................................. 48

APPENDIX
A.1 Laser Setup & Calibration for old style spring
type calibrator supplied prior to Nov 2023 ...... 51
A.2 Laser Stopping test for old style spring type
calibrator supplied prior to Nov 2023 ................ 52
A.3 Electrical Diagrams .................................................... 53
A.4 Safety & Risk Assessment Sheets .......................... 62

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1.1 SPECIFICATIONS

Order Code S970GL S902GL S906GL S908GL

Model PB-40A PB-70B PB-135B PB-135B

Estun NC- Estun NC- Estun NC- Estun NC-
Control Unit (Type)
E21 E21 E21 E21
Laser Guarding System Yes Yes Yes Yes

Nominal Pressure - Tonnage (Ton) 44 70 135 135

Nominal Pressure - Kilo-newtons (kN) 400 630 1250 1250

Machine Axis (No) 2 2 2 2

Length of Work Table (mm) 2000 3200 3200 4000

Distance Between Columns (mm) 1615 2600 2600 3200

Maximum Open Height (mm) 330 360 390 390

Backgauge Travel (mm) 520 520 520 520

Throat Depth (mm) 200 250 415 415

Ram Stroke (mm) 100 100 130 130

Motor Power (kW / hp) 4 5.5 7.5 7.5

Motor Voltage (v) 415 415 415 415

Dimensions (L x W) (cm) 270 x 180 390 x 190 390 x 200 470 x 200

Height (cm) 240 240 270 270

Nett Weight (kg) 3800 5740 8600 10350

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1.1 SPECIFICATIONS CONT.....

Order Code S909GL S910GL S912GL

Model PB-170B PB-170B PB-200B

Control Unit (Type) Estun NC-E21 Estun NC-E21 Estun NC-E21

Laser Guarding System Yes Yes Yes

Nominal Pressure - Tonnage (Ton) 176 176 220

Nominal Pressure - Kilo-newtons (kN) 1600 1600 2000

Machine Axis (No) 2 2 2

Length of Work Table (mm) 3200 4000 4000

Distance Between Columns (mm) 2600 3200 3200

Maximum Open Height (mm) 470 470 450

Backgauge Travel (mm) 550 550 550

Throat Depth (mm) 420 420 420

Ram Stroke (mm) 200 200 200

Motor Power (kW / hp) 11/15 11/15 15/20

Motor Voltage (v) 415 415 415

Dimensions (L x W) (cm) 390 x 220 470 x 220 470 x 230

Height (cm) 290 290 300

Nett Weight (kg) 11100 14100 16500

1.2 STANDARD EQUIPMENT

Front Sheet Supports
Mobile Foot Pedal Control
Instruction Manual

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1.3 IDENTIFICATION

Top Beam
Control Pendant

Side Fence E21 Control

Top Die Clamps

Mobile Foot Pedal

Front Supports Bottom Die

Hydraulic Pump
Control Pendant Arm

Back Fence
Side Fence

Tonnage Chart

Electrical Cabinet

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2.1 GENERAL METALWORKING MACHINE SAFETY

DO NOT use this machine unless you have read this manual or have been instructed in the use
of this machine in its safe use and operation

Exposure to the dust created by grinding, may

RESPIRATORY cause serious and permanent respiratory or
PROTECTION other injury, including silicosis (a serious lung
disease), cancer, and death.

DO NOT wear gloves near moving parts of the

GLOVES machines. Operator’s hands can be caught and
drawn into the rotating dies.

ALWAYS wear eye protection. Any machine can

EYE & EAR throw debris into the eyes during operations,
PROTECTION which could cause severe and permanent eye
damage.

SAFETY Safety footwear must be worn when operating

FOOTWEAR this equipment

This manual provides safety instructions on the

proper setup, operation, maintenance, and
READ & UNDERSTAND
service of this machine. Save this manual, refer
THE MANUAL
to it often, and use it to instruct other operators.

 Always wear safety glasses or goggles.

 Wear appropriate safety footwear.
 Wear respiratory protection where required.
 Gloves should never be worn while operating the machine, and only worn when
handling the workpiece.
 Wear hearing protection in areas > 85 dBA. If you have trouble hearing someone speak
from one metre (three feet) away, the noise level from the machine may be hazardous.
 DISCONNECTION THE MACHINE FROM POWER when making adjustments or servicing.
 Check and adjust all safety devices before each job.
 Ensure that guards are in position and in good working condition before operating.
 Ensure that all stationary equipment is anchored securely to the floor.
 Ensure all machines have a start/stop button within easy reach of the operator.

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2.1 GENERAL METALWORKING MACHINE SAFETY Cont.

 Each machine should have only one operator at a time. However, everyone should know
how to stop the machine in an emergency.
 Ensure that keys and adjusting wrenches have been removed from the machine before
turning on the power. Appropriate storage for tooling should be provided.
 Ensure that all cutting tools and blades are clean and sharp. They should be able to cut freely
without being forced.
 Stop the machine before measuring, cleaning or making any adjustments.
 Wait until the machine has stopped running to clear cuttings with a vacuum, brush or rake.
 Keep hands away from the cutting head and all moving parts.
 Avoid awkward operations and hand positions. A sudden slip could cause the hand to move
into the cutting tool or blade.
 Return all portable tooling to their proper storage place after use.
 Clean all tools after use.
 Keep work area clean. Floors should be level and have a non-slip surface.
 Use good lighting so that the work piece, cutting blades, and machine controls can be seen
clearly. Position any shade lighting sources so that they do not cause any glare or reflections.
 Ensure there is enough room around the machine to do the job safely.
 Understand that the health and fire hazards can vary from material to material. Make sure all
appropriate precautions are taken.
 Clean machines and the surrounding area when the operation is finished.
 Use proper lock out procedures when servicing or cleaning the machines or power tools.

DO NOT
× Do not distract an operator. Horseplay can lead to injuries and should be strictly prohibited.
× Do not wear loose clothing, gloves, necktie’s, rings, bracelets or other jewellery that can be
come entangled in moving parts. Confine long hair.
× Do not handle cuttings by hand because they are very sharp. Do not free a stalled cutter
without turning the power off first. Do not clean hands with cutting fluids.
× Do not use rags or wear gloves near moving parts of machines.
× Do not use compressed air to blow debris from machines or to clean dirt from clothes.
× Do not force the machine. It will do the job safer and better at the rate for which it was
designed.

BEFORE OPERATING ANY MACHINE, TAKE TIME TO READ

AND UNDERSTAND ALL SAFETY SIGNS AND SYMBOLS.
IF NOT UNDERSTOOD SEEK EXPLANATION FROM YOUR
SUPERVISOR.

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2.1 GENERAL METALWORKING MACHINE SAFETY Cont.

HAZARDS ASSOCIATED WITH MACHINES include, but are not limited to:
• Being struck by ejected parts of the machinery
• Being struck by material ejected from the machinery
• Contact or entanglement with the machinery
• Contact or entanglement with any material in motion

Health Hazards (other than physical injury caused by moving parts)

• Chemicals hazards that can irritate, burn, or pass through the skin
• Airborne items that can be inhaled, such as oil mist, metal fumes, solvents, and dust
• Heat, noise, and vibration
• Ionizing or non-ionizing radiation (X-ray, lasers, etc.)
• Biological contamination and waste
• Soft tissue injuries (for example, to the hands, arms, shoulders, back, or neck) resulting
from repetitive motion, awkward posture, extended lifting, and pressure grip)

Other Hazards
• Slips and falls from and around machinery during maintenance
• Unstable equipment that is not secured against falling over
• Safe access to/from machines (access, egress)
• Fire or explosion
• Pressure injection injuries from the release of fluids and gases under high pressure
• Electrical Hazards, such as electrocution from faulty or ungrounded electrical
components
• Environment in which the machine is used (in a machine shop, or in a work site)

Machines are safeguarded to protect the operator from injury or death with the placement of
guards. Machines must not be operated with the guards removed or damaged.

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2.2 HYDRAULIC PRESS BRAKE SAFETY PROCEDURE

DO NOT use this machine unless you have been instructed in its safe use and
operation and have read and understood this manual

Safety glasses must be worn at all Long and loose hair must be
times in work areas. contained or restrained

Appropriate protective footwear with Coveralls, protective clothing, or a

substantial uppers must be worn workshop apron, is recommended

Rings and jewelery must not be worn. DO NOT wear large leather gloves
when operating this machinery

PRE-OPERATIONAL SAFETY CHECKS

1. Ensure that all guards and safety devices are in position and secured.
2. Adjust all guards to minimum practicable clearances for the material to be pressed.
3. Note: any guards and safety devices should NEVER be removed, except for maintenance
purposes, and only by an authorised staff member.
4. Working parts should be well lubricated and all jaws, fingers, ‘V’ blocks and blades be free of
rust and other foreign matter.
5. Adjust the head rams to suit the material thickness.
6. Adjust and check that the ‘v’ forming blocks and/or knife blades are aligned correctly.
7. Be aware of any other personnel in the immediate vicinity and ensure the area is clear
before using this equipment.
8. Familiarize yourself with all electrical, hydraulic and mechanical operations and controls,
including the roving foot pedal control.

OPERATIONAL SAFETY CHECKS

1. Strictly only one operator is to use this heavy duty press brake, and, when necessary, with a
safety observer present.
2. Never use any press or pan brake to bend or fold beyond the capacity of the machine.
3. Ensure that both hands are positioned away from any possible pinch point
4. Particular preparation and caution is to be observed when bending rod, strap or spring
steel.
5. This heavy duty press brake is likely to be fitted with infra-red safety beams or electronic
sensors to detect hazardous circumstances. If so, this machine should NOT operate if these
safety devices are breached in any way, either by materials or by the operator.
6. Never leave the machine in operational mode while unattended.

POTENTIAL HAZARDS
 Entanglement and entrapment  Striking and shearing
n Pinch, crush and squash  Manual handling
 Electrical and hydraulic components  Eye injury

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SAFETY SYMBOLS
Fixed to the front of the press brake are safety symbols 

designed to make sure the machine is safely operated CENTRE

WORKPIECE


Hearing and eye protection are extremely important as the result of
an injury to these parts of the body may cause permanent damage.
Safety glasses and hearing protection must be approved
CENTRE
WORKPIECE


When operating the press-bake hands and arms must at all times
be kept from between the top and bottom die.
Failure
CENTREto do so may cause severe crushing.
WORKPIECE

 With all hydraulic press brakes it is important that pressing takes

place between the two rams in the center of the beam.
This ensures equal pressure is applied to both rams.
CENTRE
WORKPIECE

 Never attempt to support the end of the workpiece by holding it

on either side of the tools. No part of your body must enter the
hazardous area during bending operations. Beware of sudden
CENTRE
ORKPIECE movements of the worksheet during bending

Never hold the sheet by its folded edge; hold it from the sides

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2.3 LIFTING INSTRUCTIONS

On the day that the machine arrives, make sure that a crane with sufficient capacity is available
to unload the machine from the vehicle. Ensure access to the chosen site is clear and that doors
and ceilings are sufficiently high and wide enough to receive the machine.
To handle the machine, the slings should be positioned so the machine is level when lifted.
When using slings please take note of the sling angle and the loads that apply

Fig 2.2
When the slings are at a 45° angle then each sling is
carrying the equivalent of 50% of load weight. (Fig.2.1).

When the slings are at a 90° angle then each sling will
have a weight equal to 75% of the load on each sling.
(Fig 2.2)
Note! The manufacturer recommends not to exceed 90°
Fig 2.1.
angle

LIFTING POINTS
When lifting the machine only certified lifting slings should be used.
Ensure that when lifting, the machine does not tip over.
Check that the lifting slings do not interfere with the hydraulic pipes or electrical conduits.
Failure to follow these instructions could cause damage to the machine

Fig. 2.3

Fig.2.3

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3. INSTALLATION
3.1 SITE SELECTION AND PREPARATION

The METALMASTER Press Brake must be installed on a rigid and stable floor such as a concrete
slab 150 - 200mm thick. The press brake will be more stable if it sits on one slab and does not
straddle slabs. Due to the design of the Press Brake with a high center of gravity bolting down to
the floor is preferable.

The site must allow for access to the machine from all sides leaving enough room to cover any
maintenance programs that need to be done. The rear and front of the machine must allow for
clearance of the work parts.

If no solid foundation can be found prepare the following foundation. (Fig.3.1)

Install the machine on the prepared foundation, and then fix using the foundation bolts. Once
attached to the bolts do the final second grouting. After the cement has been solidified, check
and correct the level of the machine. Check the bolt hole dimensions on the machine.

SECOND GROUTING

150x150

600
700
100-150

200x200
430
Screw Support Plate
120 X120 X 20 - Upper surface should be at
the same level as the ground
200

75

Fig.3.1
A

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3.2 MACHINE LEVELING

To set your machine up so that it operates to optimum performance, apply the following
leveling procedure
After your guillotine has been anchored to a concrete slab floor, it then needs to be leveled. The
leveling is performed using the screws on each pad.(Fig. 3.2). Loosen the hold down bolts and
place a level on the surface of the working table. Tolerances: 1000:0.30mm, for both longitudi-
nal and transverse.
Metal plates need to be placed under each jacking screw to distribute the load. Once level then
tighten the hold down bolts.

Jacking Screw

The machine must not rest on supports

other than those defined in Fig. 3.2

Fig.3.2 Metal Plate

3.3 ELECTRICAL INSTALLATION

Place the machine near an existing power source. Make sure all power cords are protected from
traffic, material handling, moisture, chemicals, or other hazards. Make sure there is access to a
means of disconnecting the power source. The electrical circuit must meet the requirements for
415V. To minimize the risk of electrocution, fire, or equipment damage, these machines should
be hard wired with installation work and electrical wiring done by a qualified electrician.
NOTE : The use of an extension cord is not recommended as it may decrease the life of electrical
components on your machine.

ELECTRICAL REQUIREMENTS

Nominal Voltage.........................................415V
Cycle............................................................50 Hz
Phase...............................................Three Phase

(Full load current rating is on the specification plate on the motor.)

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3.4 FULL-LOAD CURRENT RATING

The full-load current rating is the amperage a machine draws when running at 100% of the out-
put power. Where machines have more than one motor, the full load current is the
amperage drawn by the largest motor or a total of all the motors and electrical devices that
might operate at one time during normal operations.

It should be noted that the full-load current is not the maximum amount of amps that the
machine will draw. If the machine is overloaded, it will draw additional amps beyond the
full-load rating and if the machine is overloaded for a long period of time, damage, overheating,
or fire may be caused to the motor and circuitry.
This is especially true if connected to an undersized circuit or a long extension lead. To reduce
the risk of these hazards, avoid overloading the machine during operation and make
sure it is connected to a power supply circuit that meets the requirements.

3.5 CHECKING THE POWER SUPPLY

METALMASTER machines are supplied wired ready to run. Check the specification plate on the
machine to confirm the local voltage is the correct voltage for the machine.
The machine must be connected to the power by a qualified and licensed electrician.
The motor direction must be checked as indicated below, to make sure the motor runs in the
correct direction.
NOTE: Warranty may be voided if it is found that the connection was not carried out by a
qualified electrician.

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3.6 ATTACHING THE ACCESSORIES.

q Bolt the support arms onto the feed table. Ensure they are level and square to the table.
(Fig.3.3)

Fig.3.3

q Unpack and attach both the side guards to the machine

making sure they are square with the machine. (Fig3.4)

Fig. 3.4

q Unpack the mobile foot control (Fig.3.5)

Fig. 3.5

q Plug the mobile foot control it into the socket provided

on the machine under the electrical cabinet. (Fig.3.6)

Fig. 3.6

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4. COMMISSIONING
4.1 PRESS BRAKE GUARDING SYSTEM - LASER GUARDING
Australian Legislation - Machine parts traveling at more than 10mm/second need physical or
electronic guarding.

Laser Guarding - This press brake top beam has an elec-

tronic guarding system, when seutp & calibrated correctly it
is designed for the protection of the fingers and arms of the
operator in close proximity to the pressbrake tooling.

There is a laser emitter, a receiver (Fig.4.5) and a laser safety

controller in a Laser set. These are an electronic safety device
that can detect obstuctions in the working area as well as
monitor relay status. The safety guarding system reacts de-
pending on what signals it gets from all these components.
Fig.4.5

Emitter - The LINK LED on the emitter will be green to advise the emitter is linked with the
receiver (Fig.4.6)

Receiver- Has a green “ON” LED (Fig.4.5) to indicate all 3 protection zones of the laser are
aligned and linked. Protection zone E1, E2 & E3 lights turn RED when there is an obstruction
(Fig.4.6)

Fig.4.6

The laser system serves two functions

• If the beam is traveling down fast and an obstruction is introduced, the laser system sends a
signal to the laser safety controller so it will stop the beam travel.

• If any laser protection zone is obstructed before the beam is moving, they send a signal to
the laser controller so it will restrict the beam travel to slow speed.

* Lasers must never be disabled. Machines must not be used if the laser system is faulty.

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4.2 LASER GUARDING SAFETY CONTROLER

On power up the laser safety controller per-

forms a self test and checks and also checks
the emitter & receiver for errors, if a safety
fault is found the laser safety controller enters
a fault state and can not be reset unless the
fault is retified.

Types of errors detected Emitter Receiver Controller

Broken or short circuit cable

Communication failure

Failure of safety output circuit

Internal circuit failure

Note: Checked, Not Checked

Laser Safety Controller Self check & Monitoring function -

E1, E2, E3 laser sensors - The laser safety controller monitors the output control signals of the
sensors and detects effective beam transmission.

Fault detection & indication - Detects the failure of the controller or laser sensors when any
failure in the above table occurs, and indicates the error at the same time.

Fast down stroke - The laser safety controller monitors the state of the NC contacts of the relay
which controls the fast down stroke to ensure the switching occurs in realtion to the safety
logic.

Slow down stroke - The laser safety controller monitors the state of the NO contacts of the relay
which controls the slow down stroke to ensure the switching occurs in realtion to the safety
logic.

OSSD outputs of controller - A Type 4 safety circuit is built in to the laser safety controller circuit
to monitor the state of the internal safety relay contacts to prevent welding due to arcing.

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4.3 LASER SAFETY CONTROLER - LAYOUT

Safety ON Indicator Safety OFF Indicator

(Green) (Red)

Normal mode Indicator

(Green)

Fault Indicator
(Red) Box mode Indicator
(Yellow)

Power Indicator
(Orange)

Mute mode Indicator

(Yellow)

Mode Switch Guarding power

switch

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4.4 LASER SAFETY CONTROLER - OPERATING MODES

The laser safety controller provides three operating modes selected via the self resetting mode
switch, rotate the mode switch to toggle between each mode, at machine or guarding system
power on the mode is always reset to NORMAL mode.

Normal mode -
In normal mode all 3 protection laser sensors E1, E2 & E3 are all active, during fast speed
(prior to the mute point) any laser sensor that is obstruted will cause the Top beam to stop,
after removing the obstruction the bending cycle can continue as normal to the mute point
(Slow speed) and perform the bending.

Boxing mode -
In boxing mode the front protection laser sensor E1 is muted, the central protection lasers
E2 & E3 still remain active, during fast speed (prior to the mute point) if laser sensor E2 or E3 is
obstruted it will cause the Top beam to stop, after removing the obstruction the bending cycle
can continue as normal to the mute point (Slow speed) and perform the bending.

This mode is designed for use only for when a work piece will interfere with the front sensor
E1, such as a pre bent side of a component. This mode must be used only by an experienced
operator and extreme caution should be taken at all times.

Muting mode -
In muting mode ALL protection laser sensors E1, E2 & E3 are muted, the Top beam will only
move in mute speed (Slow speed) regardless of any obstruction the beam will NOT STOP unless
you remove your foot from the foot pedal. The beam will move in slow speed the enitre beam
stroke and complete the bending cycle. This mode is useful for perfoming special bending
operations like hemming.

In this mode the Top beam will move slower than 10mm/s so effectivley no safety guarding
is required. This mode must be used only by an experienced operator and extreme caution
should be taken at all times.

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4.5 LASER GUARDING SETUP & CALIBRATION - (Magnet type)

** Aiming aid types have been updated over time, if this procedure does not match
your supplied aiming aid, please refer to Appendix A.1 for the old style procedure.

Setup tool - Aiming aid - The user is responsible to correctly

adjust the laser device when different length tools are used,
setup and verification of these adjustments are confirmed by
testing with the aiming aid.

Aiming aid -
• Used to align the lasers to the punch.
• Attached by magnet to the Top punch.
• Place on both ends of the tooling for alignment.
• 3 predefined reaction time settings, The reaction time is
the distance the beam travels after being told to stop.

Align TX Emitter -

• Place and aiming aid on each end of the punch tooling to be setup.
• Align the aiming aid through the see through 9mm V setting with the V of the punch tip
• Adjust the emitter mounting arm so the E2 laser runs directly through the center on the L2
hole of both aiming aids.

Align RX Receiver -

• Align the receiver mounting arm so all 3 lasers from

the Emitter (E1, E2 & E3) are all aimed in the center of
the corresponding E1, E2, E3 on the receiver.

The green “ON” LED will be illuminated at correct

alignment.

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4.6 LASER GUARDING STOPPING TEST - (Magnet type)

Option 1 : Small V Method

Use this method if you are using a smaller V size where you can easily place the Aiming Aid on
the end of the die block.

Setup :

a) Before proceding please ensure the Laser setup &

calibration has been performed as per section 4.3 of this
manual.

b) Ensure during Fast Speed, the beam is travelling at

least 50mm/s, the mute switch is not triggered, and any
other obstruction is removed during the test.

c) Place the Aiming Aid on the end of the die block. The
end of the aiming aid should extend past the top of the
die by at least 35mm as shown in the image.

Testing:

a) Raise the beam to maximum opening height.

b) With the footpedal bring the beam down (fast mode)

It should suddenly stop once it detects the obstruction.

c) Measure the clearance between the tip of the punch

and the top of the aiming aid.

TAKE CARE NOT TO ACCIDENTLY MOVE THE AIMING AID

WHEN MEASURING!

There must be at least be 5mm clearance.

d) Repeat this process on the left side.

If this test is not successful, there may be something

wrong with the laser set-up, please double check the
setup as per section 4.3 of this manual. If the test still fails
please call for service.

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Option 2 : Large V Method

Use this method if you are using a large V size where you can not easily place the Aiming Aid
on the end of the die block.

Setup :

a) Before proceding please ensure the Laser setup &

calibration has been performed as per section 4.3 of this
manual.

b) Ensure during Fast Speed, the beam is travelling at

least 50mm/s, the mute switch is not triggered, and any
other obstruction is removed during the test.

c) Place the Aiming Aid on the side of a 6mm+ piece of

steel, The end of the aiming aid should extend past the
top of the steel by at least 35mm as shown in the image.

Testing:

a) Raise the beam to maximum opening height.

b) With the footpedal bring the beam down (fast mode)

It should suddenly stop once it detects the obstruction.

c) Measure the clearance between the tip of the punch

and the top of the aiming aid.

TAKE CARE NOT TO ACCIDENTLY MOVE THE AIMING AID

WHEN MEASURING!

There must be at least be 5mm clearance.

d) Repeat this process on the left side.

If this test is not successful, there may be something

wrong with the laser set-up, please double check the
setup as per section 4.3 of this manual. If the test still fails
please call for service.

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 OPERATION MANUAL PB-GL SERIES

4.7 LASER SAFETY DEVICE PERIODICAL CHECK

The alignment & calibration of the laser system emitter & receiver along with the machines
punch tooling shall be checked using the supplied calibration & testing aids.

Section 4.5 “Laser guarding setup and Calibration” shall be used for the setup & calibration
Refer Page 22 of this manual.

Section 4.6 “Laser guarding stopping test” shall be used for performing the stopping test
Refer Pages 23~24 of this manual.

The following schedule shall be followed for periodical testing:

• At pressbrake startup
• After each tool change
• After operator change
• After each scheduled operator break
• After each operator change of shift
• Whenever the TX Emitter or RX Receiver has been moved

Note ** Over time the supplied Aiming aids for the Laser calibration & stopping tests have been
updated, if the procedure in Section 4.5 and 4.6 of this manual does not match the style of the
supplied aiming aids, please refer to Appendix A1 and A2 for the older spring type aiming aid
procedures.

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 OPERATION MANUAL PB-GL SERIES

4.8 CONTROLS
The purpose of this control overview is to provide the novice machine operator with a basic
understanding of how the machine is used during operation, and the machine controls and
what they do. It also helps the operator to understand if they are discussed later in this manual.

A D E F G

K
H I J
L M

A Control Pendant I Hydrualic Pump OFF N

B Estun E21 Controller J Mute light

C Control Panel K E-Stops

D Power ON Light L Up/Down manual buttons

E Controller Enable Switch M Button / Pedal selector

F Inch or Cycle Switch N Mobile unit

G System Error light O Up Pedal

O
P
H Hydrualic Pump ON P Down Pedal

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 OPERATION MANUAL PB-GL SERIES

5. OPERATION
The Model PB-135E will perform many types of operations that are beyond the scope of this
manual. Many of these operations can be dangerous or deadly if performed incorrectly.
The instructions in this section are written with the understanding that the operator has the
necessary knowledge and skills to operate this machine. If you are experiencing difficulties
performing any operation, stop using the machine! If you are an inexperienced operator, we
strongly recommend that you read books, trade articles, or seek training from an experienced
operator. Above all, your safety should come first!

5.1 STARTING THE MACHINE FOR THE FIRST TIME.

1. Turn the main isolation switch ON and wait for the

E21 controller and Safety unit to load. (Fig.5.1)

2. Ensure the safety controller is set in NORMAL mode

with the Normal mode light illuminated GREEN, the
Power light illuminated ORANGE and the OSSD On
(Safety On indicator) light is GREEN (Fig.5.2)

3. Press the round pump start button on the operator Fig. 5.1
panel. (Fig.5.3)

4. Press the rectangular green program start button on

the E21 controller membrane (Fig.5.3)

5. Check for any machine monitoring errors by examining

the mute light for any sequence of flashing light, if a
flashing light is observed refer to section 6.3 page 43
for a descrption of any monitoring error

6. The guarding system and machine is now active. Fig. 5.2

7. Perform Laser guarding setup & calibration as per

section 4.5 of this manual.

8. Perform Laser guarding stopping tests as per section

4.6 of this manual.

9. If calibration & test pass, then the Press Brake is ready

for operation.

Fig. 5.3

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 OPERATION MANUAL PB-GL SERIES

5.2 TESTING THE EMERGENCY STOPS

The Metalmaster Press Brake model PB-135B is fitted with two emergency stop buttons.
One is on the mobile foot pedal and the other is on the pendant control panel. They should be
tested one at a time to ensure they are working correctly.

To test the emergency stops:

1. Make sure that all the emergency buttons have been

reset

2. Start the machine and then press the emergency stop

on the pendant. The machine’s hydraulic pump should
stop and the power should be cut off. (Fig.5.5)

3. Try to restart the hydraulic pump by pressing the green

pump start button. If the pump will not start then the Fig. 5.5
emergency stop is working correctly.

4. Reset the emergency button by twisting the top red

section until the red section pops up.

5. Press the green pump start button again. The pump

should now start. The emergency stop is working
correctly.

6. Repeat steps 1-5 for each of the other emergency stop

buttons. (Fig.5.6) Fig. 5.6

5.3 SETTING THE MUTE & RETURN HEIGHTS

The PB-GL Series are fitted with adjustable return height
and adjustable mute switch positions. The Mute switch is
used to change the speed of the beam from the approach
speed to the bending speed (low speed) and should be set
carefully.

To set the heights:

1. Switch the controls to “INCH”
2. Inch the beam down until it is 14mm above the work
piece, and set the mute switch so that it is depressed. Fig. 5.7
This will now be the mute point. A B C
3. Return the top beam to the top position, then inch A = Return height setting
down the top beam until it reaches the desired return B = Actual position
point and set the return switch. This will now be the C = Mute height setting
point at which the top tool beam returns to. (Fig.5.7)

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 OPERATION MANUAL PB-GL SERIES

5.4 ESTUN E21 CONTROLLER OPERATION

SINGLE: Common page that is used by anyone who wants to re-write a job.

X - (X Back gauge actual position)

Y - (Y Ram stoke actual position)
XP - (X Program Position) - Back gauge distance from the blade
YP - (Y Program Position) - Ram stroke depth. (Test bends must be done)
DX - (Distance of Back Gauge Retraction) - Amount the back gauge will retract at mute point
HT - (Hold Time) - Dwell time at the bottom of the stroke
PP - (Program Pieces) - Number of jobs to be bent
DLY - (Delay Retraction) - Time delay in seconds for the back gauge to retract when beam
reaches mute point
CP - (Completed Pieces) - Amount of jobs that have been completed
Operation: With XP highlighted, type 50.0 and press the enter button. The controller will
save this parameter and then highlight YP ready for entry. Continue the same process until all
parameters have been entered and then press green program start button. The controller will
now find X & Y position. Once it has found position you can start to bend using foot pedal or
hand operation.
Example: This job will bend a 50mm return with a Y depth of 38. There is a 50mm back gauge
retraction with no delay. There are 20 pieces to bend and 0 pieces have been completed so far.
There is a Hold Time of 2 seconds.

PROG: Program management page

This page gives access to all the saved programs, there are 40
programs and ability to save 25 steps for each program.

Operation: Press the P (program button) until Program manage-

ment page has been located. Enter 6 and press enter, this will take
you straight to the Product Information Page for program No-6.

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 OPERATION MANUAL PB-GL SERIES

5.4 E21 CONTROLLER OPERATION

PROG: Product Information Page
This page lets you enter parameters for the pieces to be
bent.
ST - (Steps) There are 3 steps in this program
PP - (Programed Pieces) - 5 jobs to be bent
CP - (Completed Pieces) 0 pieces completed
DLY - (Delay Retraction) - 1 second time delay for the back
gauge to retract
HT - (Hold Time) - 2 seconds dwell time will start when
the top beam hits the mute switch
Retract Delay - 1 second delay for the back gauge to
retract
Operation: With ST highlighted type 3 and press the enter key, this will save parameter and PP
will then be highlighted. Continue until all desired parameters have been entered.

Example: This job has 5 pieces to be bent and each piece has 3 bends in it. There are 0 pieces
bent yet, the back gauge has a 1 second delay when retracting and a hold time of 2 seconds.

NOTE: ENSURE THAT THERE IS ENOUGH DWELL TIME TO BUILD UP PRESSURE AT THE BOTTOM
OF THE STROKE TO COMPLETE THE BEND.
PROG: Individual Cut Information Page
This page lets you enter information for each individual
bend.
X - (X Back gauge actual position)
Y - (Y Ram stoke actual position)
XP - (X Program Position) - 200mm back gauge distance
from the blade
YP - (Y Program Position) - 38 ram stroke depth. (Test
bends must be done)
DX - (Distance of Back Gauge Retraction) - 50mm back
gauge retraction
RP - (Repeat) - Set to 1 bend. (The amount of times this
bend will be done before moving to bend 2)
Operation: With X highlighted, type 200 and press the enter button. The controller will save
this parameter and then highlight Y ready for entry. Continue the same process until all desired
parameters have been entered. Once bend 1 is complete press , this will take you to bend 2 so
parameters can be entered. Once all bends have parameters arrow back to bend 1 and press
the green program start button. The controller will now find X & Y position. Once it has found
position you can start bend jobs using foot pedal or hand operation.

Example: Program 6 has 3 bends and the screen is on bend 1. Bend 1 has a 200mm return and
the ram stroke has a Y value of 38. The back gauge will retract 50mm and bend 1 will be bent
once before the controller moves to bend 2.

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 OPERATION MANUAL PB-GL SERIES

5.5 E21 PRESS BRAKE CALIBRATION: X AXIS

The Metalmaster Press Brake is calibrated before the machine leaves the factory and should
not need to be calibrated. However should the machine at any time need to be calibrated, the
following is the procedure.

1. Use a rule and manually move back gauge until it

measures 100mm between back gauge finger and
the middle of pressing V.

2. Press P until “CONST” page is located.

3. Type password (1212) and press enter to locate Teach

screen.

4. In the teach screen, highlight X, and type 100 and

then press enter.

5. Press P twice to exit and return to the “Single” page..

6. Check X = 100mm on the “Single” page.

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 OPERATION MANUAL PB-GL SERIES

5.5 E21 PRESS BRAKE CALIBRATION: Y AXIS

The model PB-135E Press Brake has no hard limit micro
switches fitted to the machine. It relies simply on the soft
limits.

The Soft limit is a Software limit that is set on the

controller

1. Start the Press Brake and take the beam up to the

maximum opening height.

2. In single screen use the “Minus” key which will take

you to the “Manual Page

3. Highlight the “Y” axis and using the minus button

move Y axis up until the soft limit stops the
movement of the ram stroke screw.

NOTE: When using the “Plus” or “Minus” key, on the “Y”

axis there is no rapid movement.

4. Press P twice to exit and take you to the Single Page

and check that Y = 1.

5. Bring the beam down until it stop on the ram stroke

screws

6 Check that the measurement between the top and

bottom die is 20mm

7. If the gap is not 20mm use the plus or minus buttons

to move the Y axis up or down until you can achieve a
20mm gap between the top and bottom die.

8. Press P until “CONST” page is located, type password

(1212) and press enter to locate the Teach screen

9. In the Teach screen, highlight Y, and type 1 and then

press enter.

10 Press P twice to exit and return to the “Single” page

and check that Y = 1.

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5.6 REMOVING & REPLACING TOOLS

Installing and Removing The Die:
To remove the die, loosen the clamp screws (Fig.5.8) and
lift the die off the machine.
NOTE: Please use safe lifting practices when removing or
replacing the die.
Install 2V-dies so that the V-groove to be used faces
the rear of the machine by considering safety in the
event of die breakage. Use the clamp screws to line-up the
die with the punch.
When using two or more dies, install them with a
clearance of about 5 mm between them. Fig.5.8

Removing Punches
When changing the tools, strictly observe the following cautions:
q Never put your hand or hands between the punches and dies, to support the punch
q Before removing the punches, switch the controls to the INCH mode and move the ram
down to the desired position,
q Turn the POWER ON/OFF switch to OFF.
q When you remove the tools with an assistant operator or operators, be sure to coordinate
your work with them.
q Be sure to remove the punches first and then the dies.

To remove the punch:

1. Loosen the fixing bolts of the punch clamping plate
or plates. (Fig.5.9) The punch drops onto the
V-groove of the die. (Fig.5.10)

2. Slide the punch sideways to remove it.

Fixing Bolts
Installing Punches Fig. 5.8
Before installing the tools, wipe off the upper beam and Fig. 5.9
punch installation surfaces and tools,

1. Slide the punch into the V-groove of the die as Fixing Bolts
shown. (Fig.5.9)

2. Determine the installation position of the punch by V-groove

sliding it left and right, and lightly tighten the
fixing bolts of the punch clamping plate or plates.

Fig.5.10

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 OPERATION MANUAL PB-GL SERIES

5.7 ALIGNING THE PUNCH AND DIE

When you reinstall the dies after removing them together with the die holders, align them
again.
To Align the Tools:
1. Start the machine.

2. Set the mode to “INCH”.

3. Loosen the die clamps. (Fig.5.11)

3. Inch the top tool beam down until the top punch
is level with the top of the die. With a rule measure
the distance from the point of the punch to each side
of the V in the die block. Adjust the die clamps until Fig.5.11
they are equal and the punch is in the centre of the V
in the die block, using he die clamps to move the die.

4. Tighten the die clamps evenly until the die is secure.

5.8 ADJUSTING THE BACKGAUGE Clamp

It is important that the backgauge height is parallel with

the bottom die, and that the sheet fingers of the back
gauge are higher than the bottom die and will not collide
into the die.

To adjust the height of the backgauge: Fig.5.12 Adjust

1. Move the backgauge so the fingers are around 50mm
from the die.
Fingers

2. DISCONNECT THE MACHINE FROM THE POWER

Lock Nut
3. Using a straightedge on the top of the bottom die,
check that the fingers just clear the die block..
Adjuster
4. If the fingers need to be raised or lowered then release
the clamp and adjust the height of the fingers
accordingly (Fig.5.12), making sure that both ends are
Fig.5.13 Clamp Screw
adjusted so that the back gauge remains parallel.
5. Once the height of the fingers has been set and the fingers have been moved to the
position required, then final adjustment if required can be made to make sure that both
fingers are the same distance from the die. If required th fingers can be moved in or out
by loosening the lock nuts and using the adjust to move the fingers. Once in position
re-lock the lock nut. (Fig.5.13)

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5.9 BENDING TECHNIQUES

There are two basic bending techniques:
- AIR BENDING
This method is commonly performed because relatively low bending forces are required
- COINING
This method requires forces approximately three to five times those of air bending. It allows the
inside radius to be coined. This method almost eliminates the elasticity of the material.
AIR BENDING
During air bending, the sheet metal retains certain amount of elasticity. An acute angle, higher
than the desired angle, is generally bent to compensate for the spring back effect. The control-
lers are designed to take into account all these parameters required for air bending. The bend-
ing chart (Fig.5.16) located on the side of the press brake shows the required force and internal
radius which can be achieved along with the other characteristics such as the thickness of the
material and the die opening,
During air bending, the sheet is in contact with the tools at three
points (A, B, C) as shown in the diagram Fig.5.14
To obtain a quality bend using air bending, it is necessary that the
die opening is between 6-12 times the sheet thickness. In this way, A
the required angle is reached before it touches the bottom of the
die. Consult the bending chart for :
1. What size die to use B C
2. What the minimum return size can be for the die being use
3. What radius will be achieved Die width
4. What tonnage it will take to bend the material per metre. 8-10 times
Fig.5.14
COINING
This type of bending is where the end of the punch presses the sheet to the bottom of the die,
rupturing the elasticity of the sheet. This then causes the sheet to be bent exactly to the shape
of the punch. (Fig.5.15)
Note! This requires special tooling to be purchased and standard tooling can not be used.
When buying this type of tooling please insure that they supply you with the correct bending
chart to suit the tooling. The forces at the end of bending are 3 to 5 times the air bending forc-
es, which causes the coining of the sheet.
NOTE: The choice of the top die radius is very important for
coining, because it determines the inside radius of the bend in
the sheet. Coining can only be performed with a punch and die
of the same angular value.
Very high bending forces must be applied. These may reach
values from 3 to 5 times those shown on the air bending chart.

CAUTION: Because coining involves very high forces, take great

care to check the strength of the tools being used
Never exceed the applicable force limits. Contact you tool sup-
plier if unable to find the values. Fig.5.15

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 OPERATION MANUAL PB-GL SERIES

5.10 TONNAGE BENDING CHART

Fig.5.16

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 OPERATION MANUAL PB-GL SERIES

5.11 ADJUSTING THE TONNAGE

The pressure adjusting regulator is used to adjust the
pressure applied between the punches and dies.

To decrease the pressure, turn the knob counterclockwise

(–) and to increase the pressure turn the knob clockwise
(+) .
The maximum pressure capacity of the machine is stated
above the gauge on your machine, The Pressure gauge
indicates the pressure applied between the punches and
dies, care should be taken to not exceed the maximum
alowable tonnage of your top & bottom tooling. Fig.5.17

5.12 TOP TOOL HOLDER WEDGE ADJUSTMENT

Each top tool holder is fitted with an adjustment wedge,

however Metalmaster advise that wedges were set at
the factory and do not recommend that the wedges be
adjusted. (Fig.6.3)
Metalmaster advise that shimming the bottom die is
quicker and will save the operator time.

NOTE: If at any time the wedges need to be adjusted we

recommend that this be carried out by a Metalmaster
service engineer
Fig. 6.3

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 OPERATION MANUAL PB-GL SERIES

6. MAINTENANCE
6.1 MAINTAINING HYDRAULIC SYSTEM
When dirt, dust, and other foreign matter are deposited in large amounts in the hydraulic cir-
cuit, the hydraulic pump may produce abnormal noise and decrease in discharge capacity, and
the ram may decrease in bending speed and vibrate. These conditions are attributable to the
plugging of the filter in the hydraulic oil tank. Remove the filters, and change them and if the
hydraulic oil is badly contaminated, then change it.

CHANGING HYDRAULIC OIL

Change the hydraulic oil after about first three months of machine operation and every year
or 2000 hours of machine operation thereafter. (The hydraulic oil should be changed entirely
even if it was added in the midway.)

NOTE: When the hydraulic oil is changed, also change the filter in the hydraulic oil tank.
To change the hydraulic oil:
1 Open the ram to the maximum opening limit.

2 Press the pump, OFF button and wait until the hydraulic
pump motor stops.

3 Turn the master POWER ON/OFF switch to “OFF”.

4 Remove all bolts fixing the top cover of the tank, and
remove the top cover. (Fig.6.1)

5 Drain the old hydraulic oil from the tank into an empty
can, using a pump. If the pump is not available, prepare Fig. 6.1
an empty can with a capacity as to match the tank
capacity, and place it below the drain plug of the tank.
Remove the drain plug to drain the old hydraulic oil
from the tank into the can.

6 Wipe the inside of the tank with a clean cloth.

7 Remove the filter from the tank and replace it with a

new filter

8. Replace the drain plug if removed.

Fig. 6.2
10. Pour new hydraulic oil into the tank until it reaches the
middle of the sight gauge.(Fig.6.2)

11. Replace the tank top cover and wipe off any excess oil

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 OPERATION MANUAL PB-GL SERIES

HYDRAULIC SYSTEM OF THE MACHINE

The hydraulic system working principles are displayed in Fig.1.

INACTIVE: When the oil pump is running, the oil feeds out, through an oil pipe and into the
valve plate and solenoid valve, then returns into the oil tank. At this time the solenoid valve
isn’t working, The No.12 valve is closed and the top beam is stationary .

DOWN FAST: When the down button is pressed, valves YV1, YV2, YV4 operate. The pressurized
oil enters into the top of the cylinders through valve No.10, and at the same time, because of
the throttle valve effect, the pressure of the oil rises. This makes valve No12, and No. 15 open
under pressure,. The beam moves down fast. The pressurized oil in the lower cavity of cylinder
returns the oil to the oil tank through valves No.12, No.7 and N0.10. The cylinders top cavity
forms a vacuum and fills the oil by valve No.15,

DOWN SLOW When the down switch is pressed, the SQ6,solenoid valve and YA1,YA4,YA5 are
activated and the single valve No.15 is closed. A small aperture inside the system restricts the
oil flow. The top beam enters work-speed,

UP FAST: When the up button is pressed the beam rises. The solenoid valve YV1 powers off
Then YV1, YV3 valves power on, and with the effect of the throttle valve, the pressurized oil
enters into the cylinder’s lower cavity from valve No.10 and No.12. The beam returns, and the
pressurized oil in cylinder’s top cavity returns to oil tank by valve No.15.
The foots-switch controls the top beam movement for inching work. The valve No.5 and No.16
adjust the working pressure of system.
The overflow valve No.13 adjusts the return pressure. The pressure should be controlled within
12Mpa.

VALVE LOGIC TABLE

YV1 YV2 YV3 YV4 YV5

INACTIVE - - - - -
DOWNWARD FAST + + - + -
DOWNWARD SLOW + - - + +
PRESSURE + - - + +
UPWARD + - + - -
DECOMPRESSED - - - + +

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 OPERATION MANUAL PB-GL SERIES

HYDRAULIC DIAGRAM

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 OPERATION MANUAL PB-GL SERIES

HYDRAULIC PARTS LIST

No. Name Type Specification Qty. Remarks

1 Oil Tank 1

2 Mesh Filter 1

3 Gear Pump 1

4 Motor 1

5 Solenoid Overflow Valve 1

6 Manometer 1

7 Solenoid Reverse Valve 1

8 Throttle Valve 1

9 Valve 1

10 Solenoid Reverse Valve 1

11 Solenoid Reverse Valve 1

12 Hydraulic Control Check Valve 1

13 Distance Compressor Valve 1

14 Oil Cylinder 2

15 Hydraulic Control Check Valve 2

16 Distance Compressor Valve 1

17 Translation Overflow Valve 1

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 OPERATION MANUAL PB-GL SERIES

6.2 LUBRICATION

Before maintaining or cleaning the machine, turn off the circuit

breaker, and relieve the residual hydraulic pressure in the machine.
Post a sign to inform other workers that the machine is under maintenance
Lubrication is very important to maintain bending accuracy and avoid machine troubles. Be
sure to appropriately lubricate the machine according to the Lubrication chart below and s also
found on the side of the machine.

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 OPERATION MANUAL PB-GL SERIES

6.3 SYSTEM ERROR LIST

PB-GL Series machines incorporate internal functional monitoring, this allows easier diagnostics
of non mechanical errors that may inhibhit the use of the Pressbrake, These errors are often not
seen by the user and generally require an experenced serivce techncian to resolve.
If an internal error occurs, the error can be diagnosed by referencing the flashing sequence
of the machines system error light found on the operator pendant. Below is a complete list of
flashing sequences and a description of the error indicated. These errors can not be reset with-
out attending to the cause of the error and the power needs to be cycled to reset the error.
System Error List - Refer to light flashing sequence
A power cycle is required to reset any error after addressing cause.
Flashes Error Possible cause

SOLID E-Stop Emergency Stop push button is triggered or rear door is open

The monitoring is not receiving the Emergency Stop signals correctly. Like-
2 E-Stop
ly due to a loose connection or faulty contact switch.
Certain contactors and relays are monitored, If one of these switches fail to
3 Relay
open, the monitoring will detect this and show this error.
The maximum speed allowed during slow travel has been exceeded. The
4 Slow speed Speed may fluctuate due to wear and tear, temperature changes, oil quali-
ty, etc.. Slow speed hydraulic valve requires adjustment.
The maximum speed allowed during fast travel has been exceeded. The
5 Fast speed Speed may fluctuate due to wear and tear, temperature changes, oil quali-
ty, etc.. Fast speed hydraulic valve requires adjustment.
The monitoring has detected the top beam has moved without the
footpedal signal. This can happen if the machine sits idle for long periods,
6 Movement
Restart the machine when ready for use. If the error persists when in use,
please contact for service.
The monitoring detecting the down signal, but no top beam movement.
The solenoid plugs on the valves located at the top of the machine have
LED lights to show if they are activated or not, if the solenoids are activated
when the footpedal is pressed but the error persists please call for service.

If the solenoids are NOT turning on, Something is preventing the beam
down movement.
7 No Movement With an E21 controller:
X and XP must be within 0.1mm of each other.
Y and YP must be within 0.02mm of each other.
If neither Axis is in position, the beam won’t move down.

NOTE: If you just installed the machine, or recently changed plug, lead,
socket. The MAIN motor might not be going the right direction. Did the
electrician who did this work confirm the motor direction was correct?

8 Comms “A” The monitoring system detected a communication fault, Call service

9 Comms “B” The monitoring system detected a communication fault, Call service

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 OPERATION MANUAL PB-GL SERIES

6.4 GENERAL TROUBLESHOOTING

Problem Cause Solution

Power switched off Turn disconnect switch ON.
The emergency STOP push Turn Emergency STOP push-
button is pushed in. button clockwise to release,
then push START button.
Hydraulic Press Brake Pump Control circuit fuse is blown. Check for a possible cause.
drive is not working Remedy cause and replace
the fuse
Loose wire connections in Check for electrical control
control circuit wiring. wiring continuity using a mul-
timeter. Repair as required.
Speed change position is Set the Mute Point correctly.
not set correctly Usually 14mm gap.
Hydraulic Press ram cycle High volume valve DOWN Check the solenoid. Repair or
down in slow speed only. solenoid is defective replace.
Light curtain has been inter- Remove obstruction inter-
rupted. rupting the light curtain
Check fluid level when press
The hydraulic fluid level is ram is in the up position. If re-
low. quired, add fluid until visible
half way up the sight gauge.
Pump inlet suction filter is Check the fluid condition.
blocked or obstructed. Replace hydraulic filter, fluid,
and hydraulic filter as re-
Hydraulic pump is noisy quired.
Hydraulic inlet piping or Check piping connections,
connections are loose” caus- O-ring at the pump to Inlet
ing the pump to ingest air. flange, and tighten inlet’
flange bolts.
Hydraulic pump shaft seal is Check shaft seal for wear or
defective, causing the pump damage. Replace if required.
to ingest air.
Control mode is set to INCH Switch to CYCLE mode, then
activate the foot switch
The ram up-limit switch is Check the limit switch me-
Press ram does not return to stuck or damaged in the chanical function. Repair or
the up-limit activated position. replace.
Loose connection or broken Check for electrical continuity
wire through to the up solenoids.
Repair or replace.

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 OPERATION MANUAL PB-GL SERIES

Problem Cause Solution

Tooling is worn in the center Re machine forming surfaces of
due to continuous forming tooling. Shim the die to compen-
Under bending in the of small parts in one location. sate for worn areas.
middle of the formed Press bed and top tool beam Re machine forming surfaces of
part. are worn in the center due to press bed and top tool beam.
continuous forming of small Shim the die to compensate for
parts in one location. worn areas.
Press Top tool beam is free Check press top tool beam ways
falling. assembly adjustment.
Inconsistency from part
to part High-pressure directional Inspect for damage or worn
control valve is defective or parts. Repair of replace.
worn.
Check material thickness at both
ends of the part. Shim the die to
Variance in metal thickness.
Unequal angle at each compensate for material thick-
end of the formed part ness variance.
Variance in tooling height Shim the die to compensate for
build-up at each end. tooling height variances
Tension bar loose Contact your service engineer.
Formed parts exhibit an
Worn ram cylinders Contact your service engineer.
inconsistent angle from
end to end Loose connecting bolts to Contact your service engineer.
the top tool beam

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 OPERATION MANUAL PB-GL SERIES

6.5 ONE PIECE 4 SIDED DIE

Models S970GL, S902GL

Models S906GL, S908GL

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 OPERATION MANUAL PB-GL SERIES

Models S909GL, S910GL S912GL

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 OPERATION MANUAL PB-GL SERIES

6.6 SEGMENTED TOP PUNCH

Models S970GL Models S902GL

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 OPERATION MANUAL PB-GL SERIES

Models S906GL, S908GL, S909GL, S910GL, S912GL

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APPENDIX

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A.1 LASER GUARDING SETUP & CALIBRATION - (Spring Type Supplied Pre Nov 2023)
Aiming aids -
• Used to align the lasers to the punch.
• Spring loaded to allow the punch to lightly press into V opening
• Place on both ends of the tooling for alignment.
• Predefined reaction time settings, The reaction time is the
distance the beam travels after being told to stop.

Setup the Aiming aids -

• Loosen the locking screw and adjust both aiming aids to 9mm
• Tighten the locking screw ensuring the 9mm setting is
maintained

Align TX Emitter -
• Place an aiming aid on each end of the punch tooling to be setup.
• Gently inch the beam down until the punch touches the V in the aiming tool
• DO NOT Compress the springs completely.
• Align the Emitter so the E2 laser runs directly through the center of the E2 hole of both
aiming aids

Align RX Receiver -

• Align the receiver mounting arm so all 3 lasers from

the Emitter (E1, E2 & E3) are all aimed in the center of
the corresponding E1, E2, E3 on the receiver.

The green “ON” LED will be illuminated at correct

alignment.

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A.2 LASER GUARD STOPPING TESTING - (Spring Type Supplied Pre Nov 2023)

NEVER PLACE YOUR LIMBS IN BETWEEN THE PUNCH AND DIE

Inspection at start-up, shift change or after laser adjustment.

The laser optical lenses must be free of any dust, ingress, and damage.

When the detection area is unobstructed, the green “On” LED on the receiver must be
ON.

Block the detection area, the green “On” LED on the receiver must turn OFF.

The beam must transition to slow speed with the punch at least 20mm from the die.

From the top of the beam stroke, bring the beam down in fast mode (+50mm/s) onto
a 35-50mm thick obstruction. The beam must stop at least 5mm above the obstruction
every time.

Repeat this obstruction test at multiple locations along the entire length of the
pressbrake.

If this test is not successful, there may be something wrong with the laser set-up,
please double check the setup as per section 4.3 of this manual.
If the test still fails please call for service.

The following schedule shall be followed for periodical testing:

• At pressbrake startup
• After each tool change
• After operator change
• After each scheduled operator break
• After each operator change of shift
• Whenever the TX Emitter or RX Receiver has been moved

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PRESSBRAKE E21
OPERATION MANUAL

ELECTRICAL SYSTEM

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P-YX-E21-BLPS-DAS-415V
2023_0
Models: S970GL ~ S912GL
A.3 WIRING DIAGRAM
PB-GL SERIES
OPERATION MANUAL

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***
*** -KM4, -KM5 only used in model
S912 (200T)
PB-GL SERIES
OPERATION MANUAL

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-KM4, -KM5 are only used in model
S912 (200T)
OPERATION MANUAL PB-GL SERIES

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PB-GL SERIES
OPERATION MANUAL

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-KA7 only used on models S970, S910, S912
OPERATION MANUAL PB-GL SERIES

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OPERATION MANUAL PB-GL SERIES

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OPERATION MANUAL PB-GL SERIES

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OPERATION MANUAL PB-GL SERIES

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A.4 SAFETY & RISK ASSESMENT

General Machinery Safety Instructions

Machinery House
requires you to read this entire Manual before using this machine.

1. Read the entire Manual before starting 14. Use correct amperage extension cords.
machinery. Machinery may cause serious injury if Undersized extension cords overheat and lose
not correctly used. power. Replace extension cords if they become
damaged.
2. Always use correct hearing protection when
15. Keep machine well maintained.Keep blades
operating machinery.Machinery noise may cause
sharp and clean for best and safest performance.
permanent hearing damage.
Follow instructions when lubricating and changing
accessories.
3. Machinery must never be used when tired, or
When 16. Keep machine well guarded.Make sure guards
running machinery you must be alert at all times. on machine are in place and are all working
correctly.
4. Wear correct Clothing.At all times remove all loose
clothing, necklaces, rings, jewelry, etc. Long hair 17. Do not overreach.Keep proper footing and
must be contained in a hair net. Non-slip protective balance at all times.
footwear must be worn.
18. Secure workpiece. Use clamps or a vice to
5. Always wear correct respirators around fumes hold the workpiece where practical. Keeping the
or dust when operating machinery.Machinery workpiece secure will free up your hand to operate
fumes & dust can cause serious respiratory illness. the machine and will protect hand from injury.
Dust extractors must be used where applicable.
19. Check machine over before operating.
Check
6. Always wear correct safety glasses. When machine for damaged parts, loose bolts, Keys and
machining you must use the correct eye protection wrenches left on machine and any other conditions
to prevent injuring your eyes. that may effect the machines operation. Repair and
replace damaged parts.
7. Keep work clean and make sure you have good
lighting. Cluttered and dark shadows may cause 20. Use recommended accessories.Refer to
accidents. instruction manual or ask correct service officer
when using accessories. The use of improper
8. Personnel must be properly trained or well
accessories may cause the risk of injury.
supervised when operating machinery.Make
sure you have clear and safe understanding of the 21. Do not force machinery.Work at the speed and
machine you are operating. capacity at which the machine or accessory was
designed.
9. Keep children and visitors away.Make sure
children and visitors are at a safe distance for you 22. Use correct lifting practice.Always use the
work area. correct lifting methods when using machinery.
Incorrect lifting methods can cause serious injury.
10. Keep your workshop childproof.Use padlocks,
Turn off master power switches and remove start 23. Lock mobile bases. Make sure any mobile bases
switch keys. are locked before using machine.
11. Never leave machine unattended.
Turn power off 24. Allergic reactions. Certain metal shavings and
and wait till machine has come to a complete stop cutting fluids may cause an ellergic reaction in
before leaving the machine unattended. people and animals, especially when cutting as the
fumes can be inhaled. Make sure you know what
12. Make a safe working environment.Do not use
type of metal and cutting fluid you will be exposed
machine in a damp, wet area, or where flammable
to and how to avoid contamination.
or noxious fumes may exist.
13. Disconnect main power before service 25. Call for help. If at any time you experience
difficulties, stop the machine and call you nearest
machine. Make sure power switch is in the off
branch service department for help.
position before re-connecting.

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Hydraulic Pressbrake Safety Instructions

Machinery House
requires you to read this entire Manual before using this machine.

1. Maintenance. Make sure the Pressbrake is turned sensing safeguarding used must have regular
off and disconnect from the main power supply Safety integrity tests and records kept. These
and make sure all moving parts have come to a records must be kept for 5 years or for the life of
complete stop before any inspection, adjustment the plant and be handed to any person that you
or maintenance is carried out. Ensure the beam relinquish control of the plant to. Tests include stop
retaining bolts on the bottom of piston rams are time measurements , safety distance calculations
checked to be tight on a regular maintenance and inspections, with operator checks and periodic
schedule. maintenance checks. (WHS Regulation 226)
2. Pressbrake Condition. Pressbrake must be 11. Overloading Pressbrake. Do not exceed the
maintained for a proper working condition. Never rated capacity of the pressbrake. Refer to the
operate a Pressbrake that has low oil levels, manual for correct capacity and bending chart.
damaged or worn parts. Scheduled routine
12. Warning Labels. Take note of any warning labels
maintenance should performed on a scheduled
on the machine and do not remove them.
basis.
13. Protective fence. Do not bridge the safety limit
3. Tooling Condition. Never operate a Pressbrake
switch of the side and rear protective fences.
with damaged or badly worn tooling. Replace if
required. 14. Support arms. Do not use support arms for
intermediate storage of workpieces.
4. Pump Direction. Pump rotation must be in arrow
direction otherwise the pump will be damaged. 15. Operation. During the bending process, the
workpiece may leap up. Therefore, the material
5. Hand Hazard. Do not insert or extend your hands
must be handled carefully.
in between bending tools, under any circumstances,
while the machine is in operation mode. Serious 16. Emergency stop. Use the emergency stop button
injury can occur. in case of any emergency.

6. Gloves & Glasses. Always wear leather gloves and 17. Level machine. Level the machine on a flat
approved safety glasses when using this machine. concrete surface by using a spirit level.

7. Authorized and trained personnel. The machine 18. Floor load for Installation. The permissible floor
must be operated by authorized and trained load, where the machine is to be installed, must be
personnel. The machine is designed to be operated accounted for.
be a single user. Using the machine with more
19. Hearing protection and hazards. Always
than one operator is forbidden, except for certain
wear hearing protection as noise generated from
maintenance situations.
machine and workpiece can cause permanent
8. Power outage. In the event of a power failure hearing loss over time.
during use of the machine, turn off all switches
20. Heating Material. Heating metal with a torch
to avoid possible sudden start up once power is
while the metal is in the bending brake will weaken
restored.
the fingers.
9. Work area hazards. Keep the area around the 21. Pinching. Prevent pinching by lowering the
Pressbrake clean from oil, tools, objects & chips.
bending brake fingers when not in use.
Pay attention to other persons in the area and
know what is going on around the area to ensure 22. Call for help. If at any time you experience
unintended accidents. Do not access the rear of difficulties, stop the machine and call you nearest
machine, while the machine is working branch service department for help.

10. Guards. Operate machine only with all protective

devices and guarding in place and operational.
Never remove, defeat or bypass. Any presence-

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 PLANT SAFETY PROGRAM
PB-GL SERIES

NEW MACHINERY HAZARD IDENTIFICATION, ASSESSMENT & CONTROL

Hydraulic Pressbrake
Developed in Co-operation Between A.W.I.S.A and Australia Chamber of Manufactures
This program is based upon the Safe Work Australia, Code of Practice - Managing Risks of Plant in the Workplace ( WHSA 2011 No10 )
Item Hazard Hazard Risk Control Strategies
No. Identification Assessment (Recommended for Purchase / Buyer / User)
B CRUSHING LOW Secure & support work material on table.
Care must be taken when removing blades.
Regular maintenance Schedule must be maintained
OPERATION MANUAL

C CUTTING, STABBING, MEDIUM Wear gloves to prevent cuts from sharp material offcuts.
PUNCTURING
DS HEARING MEDIUM Hands should be kept clear of moving parts.
Isolate power to machine prior to any checks or maintenance.
Do not adjust or clean until machine has fully stopped.
Machine must be fitted with guarding, (see workcover authority principles to machine

64
guarding for guidelines).
F STRIKING MEDIUM Ensure guards are secured properly.
Wear safety glasses.
Stand clear of falling offcuts.
Keep clear of bending material.
H ELECTRICAL MEDIUM Machine should be installed & checked by a Licensed Electrician.
All electrical enclosures should only be opened with a tool that is not to be kept with the
machine.
O OTHER HAZARDS, NOISE.L OW Wear hearing protection as required.
Plant Safety Program to be read in conjunction with manufactures instructions
Authorised and signed by:
Safety officer:
Manager:
www.machineryhouse.com.au www.machineryhouse.co.nz
Revised Date: 25th Sept 2015