Many fabrication shops still rely on the Merlin 3000 Press Brake Guarding System to protect operators at the punch and die. The 3000 series was discontinued on January 31, 2021. If your facility uses a Merlin 3000, you need a plan for maintaining the system and eventually replacing it. I.M. Services LLC can help with both.
What the Merlin 3000 Press Brake Guarding System Does
Press brakes are hard to guard because the part’s flange profile changes from bend to bend. A standard light curtain can’t allow for that. The Merlin concept, developed by ISB, learns each flange profile while the first sample part is being made. It then opens a window sized exactly for that step, so the operator never decides which beams to ignore.
Who This Page Is For
- Shops running a Merlin 3000 that need replacement parts
- Maintenance teams troubleshooting an aging system
- Safety managers planning a move to a supported controller
Merlin 3000 Replacement Parts
Replacement parts for the 3000 series are still available, but only while components last. Because stock is limited, it pays to contact us before a failure stops your press brake. We’ll confirm price and availability for the parts you need.
Upgrading to the Merlin 4000
The Merlin 4000 is the current Merlin system and the natural next step. It keeps the same learn-as-you-bend approach and adds:
- A compact touch screen HMI
- Unlimited job storage, with up to 99 steps per job
- USB backup and restore of jobs
- Built-in muting, floating beams and blanking tolerance
- Compatibility with mechanical, hydraulic and servo press brakes, up-acting or down-acting
The Merlin 4000 works exclusively with ISB’s MX4200 safety light curtains, so an upgrade usually means new curtains as well as a new controller.
How We Work
- On-site assessment of your press brake, tooling and workflow
- Engineering and integration to fit the system to your machine
- Functional safety verification, including stopping performance
- Documentation with test results and compliance alignment
- Operator training on daily checks and safe use
Our work aligns with ANSI B11.3 and ANSI B11.19. Since 2012, we’ve handled design, fabrication, installation and support as a single point of contact.
Common Questions
Is the Merlin 3000 still supported? The series is discontinued. Parts are supplied subject to component availability.
Can my Merlin 3000 light curtains be reused with a Merlin 4000? The Merlin 4000 runs only with MX4200 curtains. We’ll check your setup during the assessment.
Talk to Us About Your Merlin 3000
Call267-718-7349 or email support@im-services.net to check part availability or book a press brake safeguarding assessment.