china 3 in1 cnc copper busbar machine Instruction Manual

(Domestic General Version, compatible with FEIYING-303NCMXJ/503NCMXJ/803NCMXJ and other mainstream Chinese-made CNC three-station punching, shearing, and bending integrated machines; touch screen PLC CNC system)

CNC Three-in-One Copper Busbar Processing Machine

Important Note: Touch screen interfaces and system passwords may vary slightly between different manufacturers. This manual serves as a standardized operating template; for formal production, the original manufacturer’s instruction manual should be used as the primary reference.

Table of Contents

1. Equipment Overview

2. Safe Operating Procedures (Mandatory Reading)

3. Installation and Debugging

4. Pre-Start Checklist

5. Basic Operation of Touch Screen System

6. Three-Station Machining Operation (Punching | Shearing | Bending)

7. Die Replacement Specifications

8. Daily Maintenance

9. Troubleshooting Common Faults

10. Hydraulic Oil and Technical Parameter Reference

1. Equipment Overview

This machine integrates three independently hydraulically driven punching, shearing, and bending units; the bending station is equipped with a CNC linear scale, and the touch screen allows for setting angles, thicknesses, and springback compensation; it can process copper busbars and aluminum busbars, and is widely used in the fabrication of high and low voltage switchgear busbars.

• Station 1: Shearing (cutting)

• Station 2: Punching (round holes, oblong holes)

• Station 3: Bending (horizontal bending, vertical bending, CNC angle control)

• Power: Hydraulic system; Control: PLC + color touch screen; Actuators: Hydraulic cylinder, foot switch, safety light curtain

2. Safety Operating Procedures [Red Line Clause]

1. Operators must be trained and certified. Unlicensed or minors are strictly prohibited from operating the equipment. Wear safety shoes and work clothes, and gloves are prohibited near the moving mold area.

2. When changing molds, performing maintenance, or cleaning copper shavings, the emergency stop button must be pressed and the main power supply disconnected!

3. Throughout the entire processing process, hands are strictly prohibited from entering the punch, shears, or bending die opening/closing areas; safety light curtains must not be obstructed or removed.

4. Processing copper busbars exceeding the equipment’s rated thickness and width is prohibited; processing hard materials, cast iron, and steel plates is prohibited.

5. In case of abnormal equipment operation, unusual noises, or oil leaks, immediately press the emergency stop button, disconnect the power, and investigate. Forcing production while the equipment is malfunctioning is prohibited.

6. The hydraulic system pressure is preset at the factory; non-professionals are prohibited from adjusting the relief valve pressure.

7. Multiple people should work together under unified command to avoid accidentally stepping on the foot switch.

8. After get off work, turn off the main power, clean the workbench, and apply rust-preventive oil to the molds.

3. Installation and Debugging

3.1 Positioning

1. Place the equipment on a flat, hardened surface, release the caster brakes, and level the machine body;

2. Leave at least 800mm of maintenance space around the machine.

3.2 Hydraulic Oil Filling

Open the oil tank cover and fill with 46# anti-wear hydraulic oil. Maintain the oil level between the upper and lower marks on the oil level gauge; do not over- or under-level.

3.3 Power Wiring

Standard: Three-phase 380V 50Hz, with a reliable grounding connection.

⚠Power-on Test: If the motor reverses (oil pump has no pressure, cylinder does not move), disconnect the power and swap any two phase wires.

3.4 Exhaust Air: Power on and manually run each station 5-10 times under no-load to purge air from the oil lines. Prolonged extreme no-load impact is prohibited.

4. Daily Pre-Start Checklist:

1. Electrical: Power cord, emergency stop button, and foot switch cables are undamaged;

2. Hydraulic: Oil level, no leaks; oil pipe joints are tight;

3. Mechanical: Mold fastening screws at each station are tight; guide rails and sliders are lubricated;

4. Safety: Safety light curtains are tested and functioning correctly; protective covers are complete;

5. Molds: Cutting edges are free of chips and cracks; mold specifications match the copper busbars to be processed;

6. Workbench: Clean away debris and copper shavings.

5. Basic Operation of CNC Touch Screen

5.1 Interface Modes

· Manual Mode: Inching forward and backward, used for mold debugging and calibration.

· Automatic Mode: Mass production processing, one-button foot pedal operation for each action.

· Parameter Setting Interface: Mold parameters, copper busbar thickness, bending angle, springback compensation.

· Recipe Storage: Saves commonly used bending parameters for direct recall.

5.2 System Universal Password (Most Domestic Models)

Administrator Password: 112233 / 123456 (Varies by manufacturer) Ordinary operators are prohibited from arbitrarily modifying underlying system parameters.

5.3 Bending Station Mold Calibration Steps (Core)

1. Install the corresponding R-type bending mold (R3/R5/R6/R10);

2. Enter [Mold Parameters], input the mold number and copper busbar thickness;

3. Manually advance slowly, gently clamp the copper busbar, and record the zero point;

4. Click [Save Calibration], the system automatically records the reference; Mold calibration must be performed again when changing the mold or copper busbar thickness! 5.4 Bending Springback Compensation

Copper busbars exhibit springback during bending: Set bending angle = target angle + compensation value (typically 2~8°, with larger thicknesses resulting in larger compensation). Example: To achieve a 90° finished product, set 93°~96°, and fine-tune after trial bending.

• Detailed Processing Operation of Three Stations

Cutting station

bending station

punching station

6.1 Punching Station Operation

1. Power off, install matching upper and lower punch dies, and tighten the fixing bolts; align the upper and lower dies concentrically;

2. Loading: Place the copper busbar flat against the positioning baffle;

3. Power on, manually jog the test run to confirm no die jamming;

4. Switch to automatic mode, press the foot switch, the punch descends to punch, and automatically returns upon reaching the target position;

5. Do not place the copper busbar at an angle for punching to prevent punch breakage; ensure the oblique direction of the oblong hole die is consistent.

6.2 Shearing Station (Strip Cutting)

1. Check the gap between the upper and lower shears: Standard gap ≈ 5% of copper busbar thickness; too large a gap results in large burrs on the cut surface, too small a gap damages the cutting tool;

2. Feed the copper busbar straight into the cutting edge, leaving sufficient clamping space;

3. Start with foot pedal, automatic retraction upon completion of shearing;

4. Do not shear short pieces or small copper ends to prevent material ejection and injury.

6.3 CNC Bending Station (Flat Bending / Vertical Bending)

1. Select the flat bending die or vertical bending die according to the process;

2. Select the bending type (L-shaped, U-shaped, etc.) on the touchscreen; input: copper busbar thickness, target angle, holding time;

3. Perform a trial bending of one piece, measure the finished angle with calipers, and adjust the springback compensation;

4. Use automatic mode for mass production; bend thin busbars slowly to avoid twisting; Do not force the bending into place in one go; for large angles, it is recommended to bend in stages.

7. Standard Procedure for Die Replacement

1. Press [Emergency Stop] → Turn off the main power;

2. Manually return the hydraulic cylinder to its full return position using the control panel;

3. Loosen the die clamping bolts and remove the old die;

4. Clean debris from the die base, insert the new die, and center it correctly;

5. Tighten the bolts evenly, avoiding forced tightening on one side;

6. Power on, manually inch the die slowly to close it, confirming no interference;

7. Die replacement must be recalibrated after completion.

8. Maintenance and Care Specifications

Daily Maintenance (Per Shift)

1. Clean copper shavings from the worktable and die;

2. Apply lubricant to the slider and guide rails;

3. Check the die fastening screws;

4. Check for leaks in the oil pipes.

Weekly Maintenance

1. Clean dust from the control box fan;

2. Check the foot switch and cables for damage;

3. Apply grease to all pins. Regular Maintenance (6-12 months)

1. Change hydraulic oil; clean the oil tank filter;

2. Inspect cylinder seals; replace oil seals promptly if leaks occur;

3. Calibrate the zero point of the bending grating ruler;

4. Tighten all welded and connecting bolts on the entire machine.

9. Common Faults and Simple Troubleshooting

Table Fault Phenomenon Troubleshooting Direction

Fault phenomenon	troubleshooting direction
The oil pump motor is running, but the cylinder is not moving	Power phase reversal; solenoid valve plug loose; overflow valve pressure too low
Weak and slow movements	Insufficient hydraulic oil / degraded oil; clogged filter element; Internal leakage
Punching / shearing with abnormal noise and excessive vibration	The mold is off-center; the copper busbar is placed at an angle; the mold edges are chipped
The bending angle is unstable	Unverified mold; uneven thickness of copper busbar; mold loosening; rebound parameters not set
The foot switch is unresponsive	Emergency stop not reset; foot switch wire broken; safety light curtain obstructed
Touch screen goes black	Power switch, switching power supply failure

**Oil Pump Motor Runs, Cylinder Does Not Move:** Power phase sequence reversed; solenoid valve plug loose; relief valve pressure too low

**Weak Movement, Slow Speed:** Insufficient hydraulic oil / deteriorated oil; clogged filter element; internal leakage

**Abnormal Noise and Vibration During Punching/Shearing:** Die misalignment; copper busbar tilted; die edge chipping

**Unstable Bending Angle:** Die not aligned; uneven copper busbar thickness; loose die; springback parameters not set

**Foot Switch Unresponsive:** Emergency stop not reset; foot switch wire broken; safety light curtain obstructed

**Touchscreen Black:** Power switch, switching power supply fault

**If cylinder oil leakage, abnormal noise, or electrical short circuit occurs, do not disassemble the hydraulic valve assembly yourself; contact the manufacturer’s after-sales service.** 10. Summary of Usage Prohibitions

❌ Do not subject the mold to prolonged air pressure without material.

❌ Do not process copper busbars exceeding the maximum specifications listed on the nameplate.

❌ Do not directly wash the control box or touchscreen with water.

❌ Do not arbitrarily increase the system hydraulic pressure.

❌ Do not pile wrenches or other debris on the equipment table.

❌ Do not strike the copper busbars during bending to force correction.