CoastOne Safety Features, operating procedures, and battery replacement

What safety features does the CoastOne Press Brake system have to prevent operator injuries?

The CoastOne system has the following protections against operator injuries:

• A light curtain, laser actuated Lazersafe Laser Active Optic Protective Device (AOPD), hold-to-run control, and scanner system to stop the beam from closing and keep it stopped when an object is detected in the closing space. When a safety device is disabled or access is prevented only by a hold-to-run control, the press brake beams’ closing speed is limited to <=10 mm/s.
  This optical protection system includes a laser transmitter and receiver that continuously protects the area around the punch tip, so the operator can hold the workpiece while the brake beams close, giving the operator increased productivity.
  Unlike traditional light curtains, this system reduces operator fatigue by reducing the need to move in and out of the operating area.
• A safety foot pedal for hold-to-run control with 3 positions, where the 1^st and the 3^rd position stop the closing of the press, and the 2^nd position allows the closing.
• Programmable reduced bending speed for protection against injury caused by the deflection of a protruding workpiece.
• Side guards to prevent lateral reach from the sides of the machine into the danger zone.
• An interlocked back guard to prevent access from the rear of the machine to the danger zone.
• An emergency stop for all actuators to stop and to be isolated from the power source.

What warning signs are shown to the operator?

The following signs are posted at strategic points, warning the operator of dangers:

	Warning sign in electric cabinet door for the danger of electric shock
	Warning sign in front of the machine for the danger caused by deflection of protruding workpieces
	Warning sign in front of the machine for the danger of getting crushed between bending tools
	Warning sign in front of the machine for the danger of getting crushed between a work-piece and parts of machine

What ways are there to prevent accidents during normal operation?

When using this machine, operators should be careful and exact, because this machine is classified as a dangerous construction machine. The manufacturer does not take responsibility for any  damage to the machine or accidents that are caused by machine abuses. The warnings below should be taken into consideration when using the machine.

• Watch out for the moving tools that fingers can be caught in. If safety devices like AOPD are disabled, or the machine is designed to close only at the safety speed, the closing speed is limited to 10mm/s, and closing movement will always be stopped by releasing the pedal or pressing the pedal over the force limit to position 3. Make sure that releasing of any trapped person, described in the “Release of trapped person” section in the User Manual, is clear.
• Watch out for any deflection of protruding workpieces. In the case of a long, protruding workpiece, adjust the bending speed to 1 mm/s and increase it little by little until the bending process feels comfortable and the end of the long workpiece is not moving dangerously fast.
• Be careful when bending box-shaped parts, as fingers can be crushed between the existing, upwards protruding side of the part and the frame of the machine. Pay attention to how you hold the part; never hold the part from the end where the upwards protruding side is.
• Back gauge manual adjustments must be done through the back door. Never place hands between tools; this must be a basic rule even if power is turned off.
• Only a professional electrician is allowed to open the control cabinet door.
• After a tool change, pay attention to the programmed tool values and AOPD Incorrectly programmed tool values may lead to breaking the tools. If the AOPD is adjusted in an incorrect way, the adjustment might prevent the machine from operating correctly. See the User Manual for instructions on programming tool info and adjusting the AOPD.
• Machine toppling during transportation can cause serious injuries and break the See the “Transportation” section of the User Manual for instructions on transporting the machine safely.

What is the thickest sheet metal to be bent by the machine?

The thickest recommended sheet metal is 6 mm. For your own safety, do not use any thicker sheet metal.

Can I modify the machine?

Don’t change the construction or design of the machine any way.

Who can operate the machine?

The operator must be an adult and able to use the machine. Machine operators should be aged 16 and over. Even then, older and more experienced persons must educate a younger person to use the machine. The machine user must be in good physical condition, and should take breaks often, since fatigue is a common cause of accidents.

What should I do before operating the machine?

Before operating the machine, each time, make an overall check that the machine is fit for duty:

• Check that the tools are in good shape. If you notice a damaged tool, that tool must be replaced immediately.
• Make sure that your working area is clean, to prevent tripping or slipping.
• Make sure that the machine is recommended to be bolted on the floor.

What are some tips for optimal safety?

• Make sure you have sufficient light (the minimum requirement is 500 lux).
• Ensure that other people are not in the vicinity of the danger area when you are operating the machine.
• Stop the machine when you move away from the work area.
• Check parts for damage. Always use parts that the manufacturer delivers or recommends.
• Use extreme caution during work, and do not operate the machine if you are tired or not well.
• If you hear an abnormal sound from the machine, stop the machine and check where the sound comes from, and address the issue

What should I consider when changing the punch or die?

Consider the following when changing the tools:

• After changing the die make, sure the die is fixed properly with die fixing screws.
• After changing the punch, make sure the punch is fixed properly with punch fixing screws and that the punch’s left or right end will not exceed the punch holder’s ends.
• After changing the punch or die, make sure the active program has correct punch and die values. See the User Manual for instructions on tool info programming.
• If the machine has the Lazersafe AOPD, refer to the “Bend Info” and “Lazersafe” sections in the User Manual to perform AOPD adjustments.

What are the maximum limits for punch and die settings?

Wrong punch or die values in the program may damage the tools.  Maximum weight and lengths for punches and dies are as follows:

• C9 punch max weight Max length for punch and die 868mm.
• C12/Bull12 punch max weight Max length for punch and die 1190mm.
• C15/Bull15 punch max weight Max length for punch and die 1530mm.
• G20 punch max weight Max length for punch and die 2100mm.
• G25 punch max weight Max length for punch and die 2600mm.
• G30 punch max weight Max length for punch and die 3100mm.
• G40 punch max weight Max length for punch and die 4100mm.

What should my basic maintenance schedule be?

You should do the following every two weeks:

• Check the condition and tightness of the belts.
• Grease the ball screws and bearings.
• Grease the linear bearings of linear guidance system.
• Check that screws and nuts are tight.
• Check cable conditions.

Note: The recommend grease is NLGI class 2.

What does the manufacturer’s annual inspection include?

Once a year, the manufacturer or the manufacturer’s dealer will perform a periodic inspection of the following items. Also, after an installation or major overhaul, these same tests must be performed by the manufacturer or dealer:

• Emergency stop tested
• Interlocking of sideguards tested
• Interlocking of backguard tested
• Stopping of ram movement by both foot pedal positions 1 and 3 tested
• Functionality of all limit switches of all axes tested
• Lining and leveling of brackets of the AOPD checked
• Reference values of all axes checked
• Test bends done with accepted max error of 0,1mm

Which components need to be cleaned periodically?

Check and clean the following regularly:

• Check the ball screws and the linear guidance system to see if they need to be cleaned.
• Check the touch screen if it needs to be cleaned. 
• Be sure that Warning signs are in sight.
• Clean tools when necessary.
• Move unnecessary items away from the working area.

What should I consider when transporting the machine?

Before transporting the machine, carefully read the “Transportation” section of the User Manual, which includes important visual guidelines. Also, note the following:

• Before transporting the machine, make sure that the machine is disconnected from power.
• The machine must be lifted up by a lifting belt or by chains with a forklift or a crane.
• Lifting points and the center of gravity are shown in the “Transportation” section of the User Manual.
• Weight and dimensions are shown in the machine’s ID plate.
• Protect the machine from humidity during transportation (and always).

What obligations does the manufacturer or dealer have?

The manufacturer or dealer is responsible for the following:

• The manufacturer/dealer is responsible for the transportation of the machine to the client.
• The manufacturer/dealer is responsible for the installation of the machine, including testing, adjustments, and so on).
• The manufacturer/dealer is responsible for the training on how to use the machine.
• The manufacturer/dealer is responsible for setting the machine parameters.
  Note: Operators are not allowed to change parameters that are protected by passwords.
• The manufacturer/dealer must teach the client how the edging press works and its correct use, and also tell the client which dangers are possible when working with the machine. The manufacturer/dealer must go through the guidelines for using the machine, so that the clients won’t be unclear about any areas.
• If necessary, the manufacturer/dealer must give instructions for all client problem use cases.

How much noise does the CoastOne Press Brake make?

Following is the noise level that was measured at an operator’s place in the front of the machine.

• C9: <70dB(A)
• C12/C15: <74dB(A)
• G20-G40, Bull12-Bull15: <79dB(A)

How do I release a person trapped by the machine?

If an operator becomes trapped by the machine, do the following:

1. Turn the power off via the main switch.
2. Remove the covers above the Y-axis servo motors. Cut the timing belts by using tools designed to cut metal (for example, an angle grinder) as timing belts have steel wires inside them.
3. Force the ram/upper tool up by using one of the following methods:
   1. Manually rotate each Y-axis timing pulley clockwise (while observing above).
   2. Force the upper beam up with a hydraulic jack.
   3. Force the upper beam up with a fork lift.

When and how do I replace the Coastone Electric Press Brake batteries?

If the machine has absolute encoders in the Y-axis servo motors, these batteries must be replaced every 3 years. Do not replace the battery before drive has had power on at least for 5 minutes; the new battery must be installed within 5 minutes after disconnecting the old one.

Who can you call for CoastOne Electric Press Brake Sales and Service?

Contact Automec at (781) 893-3403 if you need assistance with your CoastOne Electric Press brake.  We can answer your questions, give your advice on a new press brake or fine the parts or service you need to keep your assembly going.