NTM SSQ MultiPro Maintenance Manual

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TABLE OF CONTENTS

CHAPTER 1……....

CHAPTER 2…........

CHAPTER 3………. CHAPTER 4……….

CHAPTER 5………. CHAPTER 6………. CHAPTER 7……….

CHAPTER 8………. CHAPTER 9……… CHAPTER 10…….. CHAPTER 11…….. CHAPTER 12…….. CHAPTER 13…….. CHAPTER 14…….. CHAPTER 15…….. CHAPTER 16…….. CHAPTER 17…….. CHAPTER 18…….. CHAPTER 19……..

APPENDEX A..…...

APPENDEX B…….

SPECIFICATIONS ..........................................................................................1

PRECAUTIONS ..............................................................................................2

MACHINE ORIENTATION ...........................................................................3

GENERAL MAINENANCE ...........................................................................5

Recommended Lubricants and Fluids ......................................................6

ELECTRICAL CONTROLS AND OPERATION ..........................................9

REEL STANDS, REELS AND EXPANDABLE ARBORS .........................16

HYDRAULIC SYSTEMS .............................................................................22

Maintenance ...........................................................................................22

Hydraulic Fluid Troubleshooting ...........................................................22

Changing Hydraulic Fluid and Filter .....................................................22

DRIVE SYSTEM ...........................................................................................26

SHEAR ASSEMBLY .....................................................................................30

BEAD AND STRIATION ROLLER ASSEMBLY.......................................34

ENTRY GUIDE ADJUSTMENT ..................................................................36

CLIP RELIEF ROLLER ASSEMBLY ..........................................................39

ENTRY DRUM ASSEMBLY .......................................................................40

WIDTH CHANGE PROCEDURE ................................................................41

PROFILE CHANGEOVER PROCEDURE ..................................................49

ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS ......................63

RUN OUT TABLES AND REMOTE LIMIT SWITCH ...............................84

QUICK CHANGE POWER PAC ..................................................................87

TROUBLESHOOTING .................................................................................89

PLC CONTROLLER .......................................................................................1

Home ........................................................................................................2

Manual Operation ....................................................................................2

Automatic Operation ................................................................................2

Job Entry ..................................................................................................3

Programming Jobs ...................................................................................3

Clear Jobs .................................................................................................4

Auto Run ..................................................................................................4

Automatic Operation ................................................................................5

On the Fly Calibration .............................................................................5

Calibration................................................................................................5

Setup: .......................................................................................................6

Status/Diagnostics: ...................................................................................7

Security: ...................................................................................................8

Coil Tracking: ..........................................................................................9

Colors .....................................................................................................10

Coil Length Calculator ...........................................................................11

ELECTRICAL SCHEMATICS .......................................................................1

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LIST OF FIGURES

Figure 1: Machine Orientation ............................................................................................................ 3

Figure 2: Mounting Foot Detail .......................................................................................................... 4

Figure 3: Entry Guide ......................................................................................................................... 7

Figure 4: Acme Shafts and Left Side Adjustment .............................................................................. 8

Figure 5: Controls ............................................................................................................................. 12

Figure 6: Main Control Cable ........................................................................................................... 13

Figure 7: Run Out Table and Remote Limit Switch ......................................................................... 14

Figure 8: Main Control Box Fuse ..................................................................................................... 15

Figure 9: QCPP E 1-6 Fuse Location ............................................................................................... 15

Figure 10: Expandable Arbor Set-Up ............................................................................................... 17

Figure 11: Expandable Reel Assembly ............................................................................................. 19

Figure 12: Material Routing.............................................................................................................. 21

Figure 13: Hydraulic System – Overview ........................................................................................ 23

Figure 14: Hydraulic System – Details ............................................................................................. 24

Figure 15: Hydraulic Fluid Level ..................................................................................................... 25

Figure 16: Drive Roll Assembly View ............................................................................................. 27

Figure 17: Gears and Shafts .............................................................................................................. 28

Figure 18: Chains Upper and Lower ................................................................................................. 29

Figure 19: Entry/Exit Views ............................................................................................................. 31

Figure 20: Shear Die Detail Views ................................................................................................... 32

Figure 21: Bead Roller Assembly ..................................................................................................... 35

Figure 22: Right Entry Guide ........................................................................................................... 36

Figure 23: Entry Guide Assembly .................................................................................................... 37

Figure 24: Tooling Rail Adjustment Handle .................................................................................... 38

Figure 25: Marker Plate & Alignment Pin ........................................................................................ 38

Figure 26: Disengaged ...................................................................................................................... 38

Figure 27: Engaged ........................................................................................................................... 38

Figure 28: Clip Relief Roller Assembly ........................................................................................... 39

Figure 29: Entry Drum ...................................................................................................................... 40

Figure 30: Entry Guide Bolts "A" ..................................................................................................... 41

Figure 31: Expandable Arbor Setup ................................................................................................. 42

Figure 32: Loading Material ............................................................................................................. 43

Figure 33: Bead Roller Alignment .................................................................................................... 44

Figure 34: Bead Roller Width Change .............................................................................................. 45

Figure 35: Shear Bolts ...................................................................................................................... 46

Figure 36: Exit Die Adjustment ........................................................................................................ 47

Figure 37: Remove Top Covers ........................................................................................................ 49

Figure 38: Removing Tooling Rails ................................................................................................. 50

Figure 39: Block Chart...................................................................................................................... 50

Figure 40: Inboard/Outboard Positions ............................................................................................. 51

Figure 41: April 2009 and later ......................................................................................................... 52

Figure 42: Machines made before April 2009 .................................................................................. 52

Figure 43: Right Side Fixed Mount Rail........................................................................................... 53

Figure 44: Profile Chart .................................................................................................................... 53

Figure 45: Left Side Fixed Mount Rail ............................................................................................. 54

Figure 46: Shown in the “A” position............................................................................................... 54

Figure 47: Tooling Rail Identification .............................................................................................. 55

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LIST OF FIGURES

Figure 48: R1 Tooling Rail Spacers.................................................................................................. 55

Figure 49: L1-1 Special Instructions................................................................................................. 56

Figure 50: Entry Guide Alignment Notches and Pins ...................................................................... 57

Figure 51: Tooling Rail Adjustment Handle .................................................................................... 57

Figure 52: Marker Plate Notch and Pin ............................................................................................ 58

Figure 53: Preparing Coil for Loading.............................................................................................. 58

Figure 54: Jogging Material thru Machine ....................................................................................... 59

Figure 55: Spacing Bead Rollers ...................................................................................................... 59

Figure 56: Removing Shear Cover ................................................................................................... 60

Figure 57: Remove Shear Bolts ........................................................................................................ 61

Figure 58: Exit Die Adjustment ........................................................................................................ 62

Figure 59: SSQ100 Roller System .................................................................................................... 63

Figure 60: SS100 Panel Profile ......................................................................................................... 64

Figure 61: SSQ150 Roller System .................................................................................................... 65

Figure 62: SS150 Panel Profile ......................................................................................................... 66

Figure 63: SSQ200/210A Roller System .......................................................................................... 67

Figure 64: SS200 Panel Profile ......................................................................................................... 68

Figure 65: SS210 Panel Profile ......................................................................................................... 69

Figure 66: SSQ450/450SL Roller System ........................................................................................ 70

Figure 67: SS450 Panel Profile ......................................................................................................... 71

Figure 68: SS450SL Panel Profile .................................................................................................... 72

Figure 69: SSQ550 Roller System .................................................................................................... 73

Figure 70: SS550 Panel Profile ......................................................................................................... 74

Figure 71: SSQ675 Roller System .................................................................................................... 75

Figure 72: SS675 Panel Profile ......................................................................................................... 76

Figure 73: FFQ100 Roller System .................................................................................................... 77

Figure 74: FF100 Panel ..................................................................................................................... 78

Figure 75: FFQ150 Roller System .................................................................................................... 79

Figure 76: FF150 Panel Profile ......................................................................................................... 80

Figure 77: SSQBP Roller System ..................................................................................................... 81

Figure 78: BP 1” Panel ..................................................................................................................... 82

Figure 79: BP 1 1/2” Panel ............................................................................................................... 83

Figure 80: Run Out Table ................................................................................................................. 85

Figure 81: Run Out Table Setup ....................................................................................................... 86

Figure 82: Cable Connections and Fasteners .................................................................................... 88

Figure 83: Pressure Switch Adjustment ............................................................................................ 89

Figure 84: Limit Switch Adjustment ................................................................................................ 91

Appendices:

Figure 85: PLC Assembly ................................................................................................................... 1

Figure 86: Serial Number Plate........................................................................................................... 1

Figure 87: Home Screen ..................................................................................................................... 2

Figure 88: Job Entry Screen ................................................................................................................ 3

Figure 89: Specify Job to Run First .................................................................................................... 4

Figure 90: Auto-Run Screen ............................................................................................................... 4

Figure 91: Calibration Screen ............................................................................................................. 5

Figure 92: Calibration Screen ............................................................................................................. 6

Figure 93: Calibration Screen ............................................................................................................. 6

iii

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LIST OF FIGURES

Figure 94: Setup Screen ...................................................................................................................... 7

Figure 95: Status Screen ..................................................................................................................... 7

Figure 96: Security Screen .................................................................................................................. 8

Figure 97: Coils Password Access Screen .......................................................................................... 9

Figure 98: Coils Screen ....................................................................................................................... 9

Figure 99: Coil Indicator ................................................................................................................... 10

Figure 100: Coils Color Screen......................................................................................................... 11

Figure 101: Length Calculator Screen .............................................................................................. 11

Figure 102: Material and Thickness Screen...................................................................................... 12

Figure 103: Coil Dimensions ............................................................................................................ 12

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CHAPTER 1

SSQ SPECIFICATIONS

SPECIFICATIONS

SSQ Dimensions: Length-13’ 7” (4.1m) Width-5’ (1.5m) Height-4’ 3” (1.3m) w/Over Head Rack 1’ 10” (.6m) w/o Over Head Rack Weight-2200 lbs. (1450kg)

SSQ on Trailer: Length-17’ 6” (5.3m) Width-7’ (2.1m) Height-6’ 3” (1.9m) with reel Weight-4800 lbs. (2200kg)

Speed: 75 ft./min. Approx. (23m/min.) Approx.

Drive: Hydraulic via chain, sprocket and gear using16 polyurethane drive

rollers.

Shear: Hydraulically Powered, Infinitely adjustable, hardened tool steel dies

and blades w/Panel Recognition Proximity Sensor

Hydraulic Fluid: 18 Gallons - 32AW

Coil Width: 15” to 30” (380mm to 760mm) Note: 30” coil width requires

Expandable Arbor or Remote De-coiler Stand.

Materials Formed: Painted Steel 30ga. to 22ga. (.3mm to .8mm) Painted, Galvanized, Aluminized

Painted Aluminum .019” to .040” (.5mm to 1.0mm)

Copper 16 oz. to 20 oz. ¾ Hard (.5mm to .7mm)

Turne-Coat Stainless Steel 26ga. (.5mm)

Controls: Standard: 12v Manual Control Box w/Length Control Limit Switch

Optional: Computer Batch and Length Control

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CHAPTER 2

PRECAUTIONS

1. Make sure the operator of the machine has read and understands this manual in its

entirety before attempting to operate this equipment.

2. ALWAYS keep covers, guards and lids mounted to machine during operation

3. OBSERVE and OBEY all safety and warning signs affixed to the machine.

4. ALWAYS adhere to and follow all local and national safety codes concerning the loading

and un-loading of reeled coils.

5. USE ONLY properly rated devices for lifting reeled coils into or out of the reel stand

assembly.

6. DO NOT wear loose clothing, jewelry etc. that could become entangled in the moving

parts of the machine when operating.

7. STOP THE MACHINE and disconnect the power before attempting to make any

adjustments, perform any maintenance or changeover procedures.

8. AVOID storing the machine outdoors for long periods of time. Cover with a tarp but

provide good ventilation to prevent condensation and rust.

9. DO NOT USE SOLVENTS TO CLEAN DRIVE ROLLERS!

10. ALWAYS EMPTY MACHINE OF MATERIAL BEFORE TRANSPORT AND

STORAGE.

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CHAPTER 3

MACHINE ORIENTATION

Figure 1: Machine Orientation

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CHAPTER 3

MACHINE ORIENTATION

Figure 2: Mounting Foot Detail

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CHAPTER 4 GENERAL MAINTENANCE

GENERAL MAINENANCE

1. Always keep covers on during operation and storage. The covers are for operator safety, but

also protect the internal components of the machine from the environment.

2. Avoid storage of the machine outdoors for long periods of time. Cover your machine with a

tarp to protect it but provide good ventilation to prevent condensation and rust.

3. Keep your machine clean. This will increase the life of the machine and make maintenance

easier. A clean machine will provide a clean product.

4. Before operating your machine, visually inspect for foreign objects debris or anything unusual.

If something doesn’t seem correct, inspect and remedy prior to operation.

5. Keep chains properly tensioned. This will add to the life of the chains and sprockets. The chains

should be just snug. An over-tightened chain is just as bad for the machine as a loose chain. Idler sprockets are provided on each chain for this purpose.

6. Lubricate the chains a minimum of every 40 hours of operation. It is preferable to use a dry

motorcycle chain lube or equivalent.

7. Lubricate the 3 main drive gears a minimum of every 30 hours of operation. Use of an Open

Gear Spray Lubricant is recommended. (Figure 17 & Figure 18 on page 28).

8. Keep Entry Guide Carriage (Figure 3 on page 7) clean and lubricate as needed Spray Lube.

9. Keep Bead Roller Carriage Shafts (Figure 21 on page 35) clean and lubricate with Spray Lube.

10. Lubricate 5 Acme Shafts (Figure 4 on page 8) with Spray Lube as needed.

11. Lubricate Mitre-Gears (Figure 4 on page 8) on ends of Acme Shafts with Spray Lube as needed.

12. Keep Arbor Cradles (Figure 11 on page 19) lubricated with Clear Grease.

13. Lubricate Arbor Nut (Figure 31 on page 42) using a grease gun with EP Grease when threads

begin to look dry.

14. Clean Forming Rollers as needed with a Scotch Brite Pad and a small amount of solvent.

15. Clean Drive Rollers with soap and water or mild solvent free spray cleaner. CAUTION: Do not

use harsh chemicals or solvents or damage will occur.

16. Lubricate both faces of the Shear Blades and Dies (Figure 19 on page 31) a minimum of once

daily with Spray Lube. More should be added as needed before the cut edges begin to deteriorate.

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CHAPTER 4 GENERAL MAINTENANCE

Recommended Lubricants and Fluids

Spray Lube for:

Shear Blades, Dies, Entry Guide, Bead Roller Carriage Shafts, Acme Shafts and Mitre Gears

Super Lube - Multi-Purpose Synthetic Dri Film Aerosol Lubricant with Syncolon (PTFE)

Catalog No. 11016

11 oz. Aerosol Can Available from: MSC Supply at 1-800-645-7270

Clear Grease for:

Arbor Cradles Synthetic Extreme Pressure, High Temperature Grease with Syncolon (PTFE) Catalog No. 71160

400 gram container Available from: MSC Supply at 1-800-645-7270

EP Grease for:

Arbor Nuts and Pillow Blocks Grease - Lubricants Type: Moly Ep Grease Catalog No. 11335

14 Ounce Container Available from: MSC Supply at 1-800-645-7270

Open Gear Spray Lubricant for:

Main Drive Gears Open Gear and Wire Rope Lubricant Catalog No. 00257659

11 oz. Aerosol Can Available from: MSC Supply at 1-800-645-7270

Hydraulic Fluid (32AW) for:

Hydraulic Tank Various Manufacturers

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CHAPTER 4 GENERAL MAINTENANCE

Figure 3: Entry Guide

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CHAPTER 4 GENERAL MAINTENANCE

Figure 4: Acme Shafts and Left Side Adjustment

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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

ELECTRICAL CONTROLS AND OPERATION

POWER CORD REQUIREMENTS

For machines equipped with a QCPP-E it is very important to follow the power cord requirement prescribed by the motor and electrical control manufacturers to maintain their respective warranties. Make sure the cord you are using is marked properly. Do not assume that because an extension cord looks heavy enough that it is the right gauge. Use of the

wrong gauge extension cord will void the warranty on motor and electrical controls.

GENERATOR USE FOR ELECTRIC MOTOR MACHINES

If a generator will be used to power the machine it must be large enough to handle the amp draw requirements of the motor. Contact your local generator supplier for proper sizing and refer to the specification plate on the electric motor. Use of an improperly sized generator

will cause a low voltage situation of the electric motor and controls which will void the warranty.

MANUAL CONTROL PANEL OPERATION:

(See Figure 5)

A. FORWARD-REVERSE Switch

This selector switch controls the direction of movement of the material through the machine. Select forward to feed material and run panel through the machine.

NOTE: For operator safety, your machine will not run continuously in reverse.

B. JOG-RUN Switch

This selector switch allows you to run the machine continuously, or jog material through the machine. Select JOG to load coil into machine and to move material through the machine in small increments until it clears the shear dies. Select run after material has cleared the shear, and you are ready to run panel.

NOTE: The LENGTH CONTROL LIMIT SWITCH must be plugged in to the Limit Switch Plug at the bottom of the Manual Control Box Assembly to run continuously.

C. START FEED (Green button at Entry and Exit End)

This button is used to activate the drive system of the machine. (Jog only unless limit switch is plugged in)

D. STOP FEED (Red button at Entry and Exit End)

This button acts as an emergency stop for the drive system when using the Length Control Limit Switch. Pressing either the entry or exit button will stop the drive

system of the machine in case of an emergency.

E. SHEAR DOWN (Green button)

Pressing this button once will cycle the shear to the bottom of its stroke and return it back to the top or home position. This is one shear cycle

F. SHEAR UP (Red button)

Pressing this button during the down cycle of the shear will immediately send it back to the top or home position.

G. EMERGENCY STOP-POWER ON (Raised Red Mushroom button)

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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

Function #1 (Power On)

Pull this button OUT prior to starting the machine.

Function #2 (Emergency Stop-Power Off)

Once the machine is running, pushing this button in will stop all functions and completely shut down the machine including the engine. If the shear is in the down cycle it will freeze it in position. The shear will default back to the top or home position once the engine or motor is re-started. This button is also used to shut the machine down when not in use. Failure to push this button in prior to storage, even

overnight, could result in a dead battery on gas engine models.

H. MOTOR START (Green button)

You must pull the Emergency Stop-Power On button out before the Start Button will function.

Press this button momentarily to start the Electric Motor machine. Press and hold this button until the engine starts on a Gas Engine model.

MAIN CONTROL CABLE

(See Figure 6)

A. The main control cable is the communication cable for the Manual Control Panel

described above and the PLC Computer Batch and Length Control Computer covered in Appendix B. This cable must be connected to one or the other in order for the machine to operate.

B. The Main Control Cable exits thru the panel below and under the left corner of the

Manual Control Panel. There are three cables there and it is the larger diameter plug of the three. It has a key and slot configuration that must be aligned before the male/female connection can be made on the Manual Control Panel or Batch and Length Control Computer. This prevents misalignment and damage to the pins.

Manual Control Panel Connection

Connect the Female end of the Main Control Cable to the panel mounted male connection located at the bottom left corner of the Manual Control Panel. Make sure that the key and slot are aligned and carefully start the threads on the connection and turn clockwise until snug.

Batch and Length Control Computer Connection

Connect the Female end of the Main Control Cable to the panel mounted male connection located in the bottom of the computer on the right side. Make sure that the key and slot are aligned and carefully start the threads on the connection and turn clockwise until snug.

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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

REMOTE LIMIT SWITCH

(See Figure 7)

Note: Your machine will not run continuously in the forward direction unless the

REMOTE LIMIT SWITCH is plugged into the machine. The Remote Limit Switch is used for panel length control. It is designed to attach to the right side of the optional RUN OUT TABLES available for your machine. Plug the female end of a 3-wire 14-gage extension cord into the limit switch, and the male end into the female Limit Switch Plug located at the bottom of the Control Panel Assembly. The length of the panel you intend to run determines length of the extension cord needed. Run out a panel to the desired length and stop the machine. Slide the Remote Limit Switch onto the bottom let of the angle on the right side of the run out table so that the ARM of the switch is against the end of the panel. Pull the limit switch back toward the shear until you hear a click in the Limit Switch Head and secure the limit switch at this location. Cut and remove the set up panel from the table. Push the start button and run the next panel allowing the limit switch to stop the machine. Measure this second panel before cutting to determine if it stopped in the correct position and make the necessary adjustment to the limit switch to obtain the desired length. Repeat as necessary.

FUSES

(Figure 8)

All machines, gas or electric powered, have a 10-amp time delay fuse inside the Electrical Control Panel Assembly. This fuse protects the electrical components. If the fuse is blown, you will lose all functions of the machine except Motor Start. To replace this fuse: Loosen all 4 cover screws and open the front panel of the Control Box. Locate the automotive style inline fuse near the bottom right hand corner. It is a spring loaded twist lock holder. Push together and turn to open. Check the fuse with a continuity tester. If it is bad, replace with a new fuse and re-connect spring loaded holder.

ELECTRIC MOTOR MACHINES

(Figure 9)

Electric motor machines have an additional 10-amp time delay fuse protecting the logic circuit of the Contactor Box. This fuse holder is mounted in the side or top cover of the contactor box located approximately mid machine on the right side. Access can be gained by removing the center left side cover. This is a panel mounted, spring loaded fuse holder. To replace this fuse: Push in on the cap and turn counterclockwise to release fuse. Check fuse with a continuity tester. If the fuse is bad replace with a new fuse. To re-install, insert fuse into cap. Install fuse and cap assembly into receptacle, push down and turn clockwise to lock in place.

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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

Figure 5: Controls

Page 18

CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

Figure 6: Main Control Cable

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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

Figure 7: Run Out Table and Remote Limit Switch

Page 20

CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION

Figure 8: Main Control Box Fuse

Figure 9: QCPP E 1-6 Fuse Location

Page 21

CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS

REEL STANDS, REELS AND EXPANDABLE ARBORS

EXPANDABLE ARBOR

(Figure 10) The Expandable Arbor adjusts to accommodate coils with 16” to 20” inside diameters by expanding into the ID of the coil.

THREADED NUT

The threaded nut should always be on the right side of the machine and the tail of the coil should always be routed over the top and pointing toward the exit or shear end of the machine. This threaded nut is used to increase or decrease the outside diameter of the arbor. Turning the nut clockwise will increase the outside diameter of the arbor, and counter-clockwise rotation will decrease the arbor size. There is a grease zerk in the collar of the threaded nut that should be lubricated at least twice a year, or whenever grease in not visible on the threads of the shaft.

END COLLAR

The End Collar has two positions. Position “A” is used for coils with inside diameters of 16”. Position “B” is used for coils with inside diameters of 20”.

To adjust from one position to the other, remove 2 screws “C” until end collar is free to slide. Slide it to the inside position for 20” ID or outside position for 16” ID coil. Align it to the respective threaded holes in the reel shaft. Re-insert and tighten "C" bolts to lock the end collar to the shaft.

LOADING EXPANDABLE ARBORS WITH COIL

1. Using the Threaded Nut, collapse the arbor small enough to fit into the inside diameter of

the coil.

2. Slide the Expandable Arbor into the center of the coil making sure the threaded nut is on the

right and the tail of the coil is over the top and pointed toward the exit end of the machine.

3. Turn the Threaded Nut clockwise until the Support Bars on the arbor are just snug against

the inside of the coil.

4. Using the Reel Set Up Chart, (Figure 10), find the “D” dimension that corresponds to the

profile you are using.

5. Slide the arbor left or right to get the correct “D” dimension measuring from the edge of the

coil to the end of the Support Bar on the Threaded Nut side.

6. Finish by rotating the Threaded Nut clockwise until the Support Bars are very tight against

the inside of the coil. Verify that dimension “D” is correct, and re-adjust if necessary. The Coil and Arbor are now ready for loading. (see LOADING REELED COIL on page 20)

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CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS

Figure 10: Expandable Arbor Set-Up

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CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS

CAUTION: Always use properly rated lifting devices to load and unload coils.

Maximum Capacity / Reel: 3,000 lbs. Total Capacity for Reel Stand: 6,000 lbs.

1. The reel shafts must rest in the cradles on the reel rack. Keep the cradles lubricated with

synthetic lube to minimize wear. (Figure 11)

2. Use the Hold Down Bars on each cradle to secure the coil and reel to the reel stand during

both operation and transit of the machine. The Hold Down Bracket should be used to keep the coil from uncoiling too fast during the fabrication of panels. Apply just enough drag to keep coil tensioned. (Figure 11) Caution: Do not over tighten Hold Down Bars during machine operation. This will cause excessive load on the drive and electrical systems and premature failure will result. Do tighten Hold Down Bars tightly prior to transport of the machine.

3. If a Remote Decoiler is used it should be placed 8 to 10 feet behind the machine. Align it as

close as possible to the Right Side Entry Guide line of fire, making the side of the coil and reel parallel to the machine. NOTE: The closer the Decoiler and reel are set to the machine, the more critical this alignment becomes.

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CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS

Figure 11: Expandable Reel Assembly

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CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS

LOADING REELED COIL

Caution: Always use a forklift or other approved lifting device to load or unload Fixed Reels or Expandable Arbors loaded with coil. The Lifting Holes in the Fixed Reel sides are provided to make loading safer and easier. DO NOT use lifting straps through the lifting holes as the sharp edges may cut the straps.

1. Prepare the reel stand by making sure the Hold Down Bars are in the unlocked and open

Position (Figure 11).

2. Using an approved lifting device, lift the reeled coil into the cradles on the reel stand making

sure that the tail of the coil is in the correct position (Figure 12) then remove the lifting device.

3. Rotate the Hold Down Bars (Figure 11) to the closed position and thread the handle onto the

hold down bolt. If you are going to run panel from this coil, tighten the left and right handle just snug. Final adjustment of tension should be made while running a panel to keep reel from unwinding material too fast. As the coil becomes smaller, re-adjustment will need to be made.

Caution: Do Not over tighten Hold Down Bars. Drive and/or electrical system failure may occur.

4. If you are going to transport the machine after loading coil, tighten the Hold Down Bars

securely to keep coil from unwinding during transport, and secure the loose end of the material to the coil.

5. Before transporting the loaded Expandable Arbor, you should also secure the coil around the

outside edges through the inside diameter using a strap, rope, etc. to prevent the coil from telescoping (Figure 10).

NOTE: Make sure Hold Down Bars are tightened securely and coil is properly tied off before transporting machine.

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CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS

Figure 12: Material Routing

Page 27

CHAPTER 7 HYDRAULIC SYSTEMS

HYDRAULIC SYSTEMS

Maintenance

(Figure 13) The hydraulic system for your machine is a very durable and reliable system. It must be properly maintained to ensure trouble free operation and longevity. The factory has installed a 32 weight AW hydraulic fluid. Because this equipment is used primarily outdoors and exposed to the elements, it is recommended that the oil be changed annually. Hydraulic oil will degrade if it remains stagnate in the system for long periods of time. Check the fluid level weekly. It should be approximately 5” below the top of the filler neck. When checking the fluid level, also note the color and condition of the fluid. It should be clear in color.

Hydraulic Fluid Troubleshooting

CONDITION SOLUTION

1 White milky color indicates water contamination. Change the fluid.

2 Dark fluid usually indicates a dirty oil filter. Replace the oil filter.

3 Foamy fluid will cause a noisy pump and slow erratic

operation of the system. The cause is usually low oil level or air in the system.

4 Machine runs slow after continuous operation. Check

hydraulic fluid temperature, it should be no more than 140°F (60°C).

Check fluid level and bleed off air by pushing the shear down button and holding for 10 seconds.

Allow to cool down. Move to a shaded area if possible.

Changing Hydraulic Fluid and Filter

(Figure 14 & Figure 15) The hydraulic fluid should be changed at least once a year. More frequently if the machine is constantly in operation in a dusty environment or if the fluid becomes contaminated. To change the fluid:

1. Remove the Left Side Covers and set aside.

2. Locate the Drain Hose “A” coiled up behind the Hydraulic Filter “B” and the Drain Valve

“C” located on the bottom of the Hydraulic Tank “D” on the Filter end of the tank.

3. Remove Filler Cap.

4. Uncoil Drain Hose and hang over the side of the machine and trailer.

5. Place a container under the hose to catch the old fluid.

6. Open the Drain Valve and drain the fluid into the container. Discard of Properly.

7. Loosen, remove and discard the used Hydraulic Filter.

Page 28

CHAPTER 7 HYDRAULIC SYSTEMS

8. Re-install the new hydraulic filter and fill the tank with fresh 32 weight fluid until it is 5”

below the top of the Filler Neck “F” (approximately 18 gal).

Figure 13: Hydraulic System – Overview

Page 29

CHAPTER 7 HYDRAULIC SYSTEMS

Figure 14: Hydraulic System – Details

Page 30

CHAPTER 7 HYDRAULIC SYSTEMS

Figure 15: Hydraulic Fluid Level

Page 31

CHAPTER 8 DRIVE SYSTEM

DRIVE SYSTEM

(Figure 16, Figure 17 & Figure 18) The drive system of your machine consists of eight top and eight bottom polyurethane drive rollers. They are divided into groups of 2 per assembly making 4 Top Drive Roll Assemblies and 4 Bottom Drive Roll Assemblies. They are connected together via chain and sprocket and there are chain tensioner’s on each assembly. The drive system is powered by a hydraulic motor which transfers power to the drive assemblies using spur gears and a top and bottom drive shaft.

1. Clearance between the top and bottom drive rollers is factory set at ¾ of a turn of

pressure past the point of contact. This will drive material up to 22ga. though the machine without the need for adjustment. If adjustment becomes necessary due to slippage, you can add pressure. Do not add more than ¼ turn beyond the factory setting. It is important to adjust only one end of each assembly at a time to maintain side to side alignments. To add pressure: Loosen two Lock-Down Bolts “B” 1/8 of a turn. Loosen lock nuts on two corresponding Jack Bolts “A”. Tighten Bolts “A” 1/8 of a turn. Re-tighten 2 lock nuts on Jack Bolts “A” to lock in adjustment. Repeat this procedure on the other end of the Drive Assembly and repeat for the other 3 drive assemblies. Test for result and repeat one more time if necessary. To remove pressure: Loosen two lock nuts on Jack Bolts “A”. Loosen two Jack Bolts “A” 1/8 of a turn. Tighten two corresponding Lock-Down Bolts “B” 1/8 of a turn. Tighten two lock nuts on Jack Bolts “A” to lock in adjustment. Repeat this procedure on the other end of the Drive assembly.

2. There are three different chain tensioners on your machine. A. The first are located in slots on the side plates of the Drive Roll Assemblies. They

follow the chain locations alternating from one side to the other. To adjust, slightly loosen the nut on the bolt holding the tensioner sprocket in place. Using a dead blow hammer tap the tensioner assembly toward the drive roller until the chain is snug. Lock into position by tightening the bolt on the assembly.

B. The second type is similar. These are located on the top and bottom spreader bars

located between the Drive Roll Assemblies. These are used in the same way except there is a bolt located in the edge of the slot on the assembly used to push the tensioner assembly toward the Drive Roller to tension the chain.

C. The third is located on the Top #1 Spreader Bar between the sprocket and drive

roller. (see detail ‘A” Figure 18) Loosen two “D” bolts enough so that you can move the tensioner assembly up toward the chain until snug. Re-tighten the two “D” bolts.

3. The chains used in this system are #50 Roller Chain. See Figure 18for chain locations and lengths if chain replacement is necessary.

4. The polyurethane drive rollers will eventually need cleaning. This will become evident when they start leaving a stripe the width of the drive roller on the formed panels that doesn’t come off easily or if you run material with an oily film on it. Avoid cleaning the drive rollers with harsh chemicals or solvent. These products will attack the polyurethane and cause irreversible damage. Use of these products will void the

warranty on the drive rollers.

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CHAPTER 8 DRIVE SYSTEM

Clean the rollers with mild soap and water and a rag. Caution must be taken around

the moving parts of the machine during the cleaning process.

5. Covers should be kept on the machine during operation and storage. Ultraviolet light

will attack the polyurethane drive rollers and cause deterioration. Again, this type of damage is not covered under the warranty.

Figure 16: Drive Roll Assembly View

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CHAPTER 8 DRIVE SYSTEM

Figure 17: Gears and Shafts

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CHAPTER 8 DRIVE SYSTEM

Figure 18: Chains Upper and Lower

Page 35

CHAPTER 9

SHEAR ASSEMBLY

OPERATION

Push the SHEAR DOWN button to activate the shear cycle and cut material. IN CASE OF AN EMERGENCY: Push the SHEAR UP button during the down cycle to immediately send the shear up to the home position.

The shear is electrically activated and hydraulically driven. The two Top Limit Switches and single Bottom Pressure Switch control the cycle of the shear. The Top Limit Switches electronically lock out the drive system when the shear is in motion. The Bottom Pressure Switch sends the shear back up once the set pressure is reached.

SHEAR ADJUSTMENTS

Bottom Shear Dies (Detail A - Figure 20)

1. Bottom dies should be adjusted 1/32” below the bottom corners of the panel. Loosen the (2)

“A” bolts on the left and right Front Vertical Plates. Loosen the (2) lock nuts on the (2) Height Adjustment bolts “B”.

2. Tightening bolts “B” will lower the shear, and loosening them will raise it. Adjust each side

as needed to properly set the bottom dies to the correct spacing from the bottom corners of the panel.

3. After adjustments have been made, tighten (2) “A” bolts and (2) Lock Nuts on Height

Adjustment Bolts “B”.

CHANGING ENTRY AND EXIT SHEAR DIES

(Figure 19 & Figure 20) The Entry and Exit Shear Dies are specific to each roller set and must be changed when changing profiles. Refer to the PROFILE CHANGEOVER PROCEDURE for instruction on changing dies.

ADJUSTING THE ENTRY AND EXIT SHEAR DIES

(Figure 19 & Figure 20)

1. The Male and Female entry and Exit Shear Dies must be adjusted to the proper distance from

the vertical legs of the panel. The outside vertical leg of the male and female Entry Dies should be approximately 1/32” away from the outside of the vertical legs of the panel. The Exit Dies should be slightly to the outside of the male and female Entry Dies so that after a cut is made, the panel does not hang up on the Exit Dies.

2. Each Shear Die Holder is held in position by (2) “C” bolts passing through slotted holes at the

bottom edge of the holder, and threaded into the Entry and Exit Shear Plates.

3. Visually sight thru the male and female entry dies. Rough align them to the forming tool “line

of fire” by moving them side-to-side. If necessary, remove bolts “C” and slide the Die Holders left or right until you find two mounting holes that will work for proper alignment, then re-install bolts “C”. Tighten them just enough to hold the dies in position.

4. Jog the material through the machine and stop about 2 inches from the Entry Shear Dies.

Now re-sight the alignment of the Male and Female Dies to the actual legs of the panel and move them accordingly to assure the panel will pass through without hanging up. Carefully jog material through the shear dies. Final adjust Entry and Exit Dies as follows: The Male

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CHAPTER 9

SHEAR ASSEMBLY

and Female Entry Dies should be 1/32” or less away from the back side of the vertical leg of the panel. The Male and Female Exit Dies should be adjusted slightly to the outside of the entry dies so that the cut edge of the panel clears the dies without interference when passing through after a cut. Once alignment of the dies is achieved, tighten all “C” bolts. Jog the material out approximately 2”. Engage the shear to cut to 2” piece off. Inspect the cut made on this piece and the piece still in the machine by jogging it out another 2” so it can be viewed. If the cut is not satisfactory, re-adjust as necessary.

Figure 19: Entry/Exit Views

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CHAPTER 9

SHEAR ASSEMBLY

Figure 20: Shear Die Detail Views

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CHAPTER 9

SHEAR ASSEMBLY

TOP SHEAR BLADE ADJUSTMENT

(Figure 19 & Figure 20 – Details B & C) The Top Shear Blades are bolted to the Blade Adjustment Bar. This bar is bolted to the Top Blade Holder, and can be moved from left to right to align the blades to the Die Holders.

1. Loosen the 7 “D” bolts in the slots at the top entry side of the shear so that the Blade

Adjustment Bar will move from side to side.

2. The point of the Top #1 Blade should always be inboard of the Female vertical leg of the

panel, and should not pierce the top horizontal leg of the profile. The rake or angle of the blade should cut in a scissor action outward against the leg. The #2 Top Blade must be adjusted simultaneously in the same manner for the Male leg. You should be able to find a position that works for both Male and Female legs. Once the Blade Adjustment Bar is in the correct location, tighten all “D” bolts.

3. Jog the panel out approximately 12” and make the first cut. Check the piece to make sure the

cut is acceptable. Carefully jog the material through the shear dies making sure the panel does not get caught on the Male or Female exit dies. If the panel gets caught on the exit dies, fine tune the adjustment of the dies to correct the problem following the procedures above.

MAINTENANCE

1. Clean and lubricate the Top Blades, Bottom Dies, and Male/ Female dies at least once a day

during normal use, or whenever cutting surfaces look dry. Proper lubrication is essential to clean cuts, rust prevention and longevity.

Super Lube - Multi-Purpose Synthetic Dri Film Aerosol Lubricant with Syncolon (PTFE) Catalog No. 11016 11 oz. Aerosol Can Available from:

MSC Supply at 1-800-645-7270

Page 39

CHAPTER 10

BEAD AND STRIATION ROLLER ASSEMBLY

1. The Bead / Striation Roller assembly (Figure 21) is located behind the shear and

is accessed by removing top cover #3. These rollers can be engaged or disengaged as needed and can also be moved left or right to accommodate different panel widths.

2. The bottom bead or striation forming roller should be set 1 /32” above the drive

roller to ensure proper entry into the shear. If adjustment is necessary, loosen the four frame mount bolts “B”, and lock nuts on the two vertical adjustment bolts “A”. Raise or lower the roller assembly by using the vertical adjustment bolts “A” to obtain the proper height. Then re-tighten the mount bolts and lock nuts on the two adjustment screws “A”.

3. Next loosen the eccentric shaft lock down screw “C”. Place a 5/32” Allen

Wrench in the small hole at the end of the eccentric shaft, and rotate the top roller up until it clears the bottom roller. Loosen the two top and two bottom slide lock down screws “D”. Bring the panel material up to the rollers but not past them. SHUT OFF THE MACHINE AND DISCONNECT THE POWER BEFORE CONTINUING. Locate the bottom rollers to the desired position by sliding the assembly on the bottom slide bars. Tighten the bottom slide lock-down screws ”D”. Restart the machine and back up the panel until you gain access to the top slide lock-down screws, AGAIN SHUT OFF THE MACHINE AND DISCONNECT THE POWER. Loosen the top slide lockdown screws, and slide them into position so the top roller is directly over the bottom roller. Tighten the top slide lock-down screws “D”. Next rotate the eccentric shaft down to the desired bead depth. DO NOT go below .045” minimum clearance; excessive bead depth will distort your panel. Re-tighten screws “C”.

4. Keep slide bars lightly greased to allow bead or striation assemblies to slide

smoothly.

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CHAPTER 10

BEAD AND STRIATION ROLLER ASSEMBLY

Figure 21: Bead Roller Assembly

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CHAPTER 11

ENTRY GUIDE ASSEMBLY

ENTRY GUIDE ADJUSTMENT

(Figure 22 & Figure 23) The entry guides are used to set the material to the correct position in relation to the forming rollers of the machine. They also hold the material and feed it straight into the machine. If the entry guides are not set correctly the material will not feed into the machine properly.

1. The Right Entry Guide is set to the Tooling Rail Marker Plate mounted to the

R1 Tooling Rail.

2. To align, loosen the two “A” Bolts on the Right Entry Guide. Slide the entry

guide to the left or right until the alignment pin which is located at the end of the top shoe of the entry guide, is directly under one of the notches on the Tooling Rail Marker Plate. Make sure to choose the notch that corresponds to the desired leg configuration as noted on the decal on the top of the marker plate.

3. Tighten the two “A” bolts.

4. Loosen bolt “A” on the left entry guide.

5. Cut a 12” long piece of gage material from the coil you will be using, to set the

left entry guide.

6. Slide gage material between the left and right entry guides.

Figure 22: Right Entry Guide

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CHAPTER 11

ENTRY GUIDE ASSEMBLY

7. Slide the Left Entry Guide to the left or right to accept the new coil width. Make

sure that the coil is captured snugly between the entry guides and re-tighten the two “A” bolts.

Figure 23: Entry Guide Assembly

LEFT TOOLING RAIL TO ENTRY GUIDE ALIGNMENT

(Figure 24 to Figure 27) The Tooling Rail Adjustment Handle is used to move the Left Tooling Rails assemblies

to the left or right to align them to the Left Tooling Rail Marker Plate whenever a width change or tooling change has been made.

1. Using the Tooling Rail Adjustment Handle (Figure 24) align the notch on the

tooling rail marker plate to the alignment pin located in the Left Entry Guide. Make sure to choose the notch that corresponds to the desired leg configuration as noted on the decal on the marker plate (Figure 25). The Tooling Rail Adjustment Handle is spring loaded to allow it to disengage from the width adjustment gear (Figure 26). Press the handle inward (Figure 27) to engage the width adjustment gear and turn the handle clockwise to move the tooling outward or counterclockwise to move it inward.

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CHAPTER 11

ENTRY GUIDE ASSEMBLY

Figure 24: Tooling Rail Adjustment Handle

Figure 25: Marker Plate & Alignment Pin

Figure 26: Disengaged

Figure 27: Engaged

Page 44

CHAPTER 12

CLIP RELIEF ROLLER ASSEMBLY

1. Clip Relief Rollers (Figure 28) provide a raised area next to the male and female

legs of the panel. This helps hide the clip and screws used in installation. They rollers can be engaged or disengaged as needed.

2. Find the Tooling Rail Sheet corresponding to the profile installed in your machine

(Figure 59 - Figure 79).

Note the location of clip relief assembly’s on left and right tooling rails, and locate them on the tooling set in your machine.

3. To engage the clip relief rollers loosen lock down screw “A” and insert a 5/32”

allen wrench into the small hole on the top eccentric shaft “B”.

4. Rotate the eccentric shaft to engage or disengage the top roller assembly from the

bottom roller assembly. Adjust both left and right bead assemblies to the desired depth using a feeler gage. Recommend factory setting is 0.080 inches gap between top and bottom rollers.

NOTE: The FF100 and FF150 profiles must always be engaged for proper male/female lock to occur.

Figure 28: Clip Relief Roller Assembly

Page 45

CHAPTER 13 ENTRY DRUM ASSEMBLY

ENTRY DRUM ASSEMBLY

The Entry Drum Assembly is necessary when feeding coil off of the optional DR1/ Dual Overhead Reel Stand. It allows you to route the material around the drums to get the painted side of the coil on the top as it enters the machine. Without this assembly, you could only feed coil from a remote arbor and stand lined up behind the machine. The Entry Drums need to be adjusted whenever a width change is made. To adjust the entry drums:

1. Using a 3/16” allen wrench, loosen the four Shaft Collars “E”, on either side of

Left Entry Drum and Center Entry Drum. (Figure 29)

2. Slide the Left Entry Drum over until it is lined up with left edge of the new coil

and align the Center Entry Drum equally spaced from the Left and Right Entry Drums.

3. Slide the four Shaft Collars “E” against the sides of the drums and lock them into

place.

4. If you are making a Roller System Change, you may have to move all three drums

using the same procedure described above.

Figure 29: Entry Drum

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CHAPTER 14 WIDTH CHANGE PROCEDURE

WIDTH CHANGE PROCEDURE

CAUTION: Always make sure your machine is shut down prior to making any adjustments. DO NOT reach through the opening of the shear while the machine is running. EVER! To do so could result in serious injury.

1. Loosen the two “A” bolts on the Left Entry Guide (Figure 30). Slide the entry

guide to the left or right to accept the new coil width.

Figure 30: Entry Guide Bolts "A"

2. Make sure that the coil is captured snugly between the entry guides and re-

tighten the two “A” bolts.

3. Using the Tooling Rail Adjustment Handle “B” (Figure 24) align the notch on

the tooling rail marker plate to the alignment pin located in the Left Entry Guide. Make sure to choose the notch that corresponds to the desired leg configuration as noted on the decal on the marker plate (Figure 25). The Tooling Rail Adjustment Handle is spring loaded to allow it to disengage from the width adjustment gear (Figure 26). Press inward on the center of the handle and turn (Figure 27) to engage the width adjustment gear. Turn the handle clockwise to move the tooling outward or counter-clockwise to move it inward.

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CHAPTER 14 WIDTH CHANGE PROCEDURE

4. Load material onto the Expandable Arbor and align it to the correct position

using the chart on (Figure 31). Note: Also see REEL STANDS, REELS AND EXPANDABLE ARBORS for more information.

Figure 31: Expandable Arbor Setup

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CHAPTER 14 WIDTH CHANGE PROCEDURE

5. Load the reeled coil onto the machine using a fork lift or other rated lifting

device. Making sure the tail of the coil goes over the top and points toward the shear end of the machine. See coil routing diagram (Figure 12).

6. Cut a 1” triangle of off the 2 leading corners of the coil and feed it into the

entry guides. (Figure 32)

7. Start the machine and use the Jog button on the Manual Control Box or

Computer, to jog the material through the machine 6 to 8 inches at a time until it exits the last forming stations, and is about 1” from the Bead Roller Assembly. (Figure 21).

SHUT YOUR MACHINE DOWN BEFORE PROCEEDING.

Figure 32: Loading Material

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CHAPTER 14 WIDTH CHANGE PROCEDURE

Figure 33: Bead Roller Alignment

8. If you require beads in the panel, determine the spacing needed. For Example:

a 12” wide panel with 2 beads centered on the panel would give you 3 equal spaces or 12” divided by 3 equals 4” from center to center of each bead. Hook the end of you tape measure on the outside bottom corner of the female leg. Use a magic marker or grease pencil to mark the 4” and 8” locations on the panel. You now have 3 equal spaces.

9. Loosen the slide lock bolts on the top and bottom bead assemblies (Figure 34)

and slide each bottom and top roll assembly left or right to center them on the 4” and 8” marks on the panel.

10. Lock the two top bead assemblies in the correct position by tightening the

slide lock bolt “D” on each assembly. Next align the bottom bead rollers to the tops so that the ends of the top and bottom rollers are flush with each other and tighten the bottom slide lock bolts on these 2 assemblies.

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CHAPTER 14 WIDTH CHANGE PROCEDURE

BO L T " A"

LOCK N UT

BOL T "B"

BOL T "A"

LOCK N UT

BO LT "B "

BOL T "B"

SID ES FLU SH

PAS S LIN E

BO LT "B"

BO LT "D"

HOLE FO R HEX WREN CH

BO LT "C"

11. Check the gap between the top and bottom bead rollers using a feeler gauge.

An approximate setting of 1½ times the material thickness is recommended. This setting can be adjusted slightly in either direction according to preference.

12. To set or change the gap between top and bottom beads, loosen the "C" bolt

on both top rollers (Figure 34).

13. Insert the correct feeler gage between one of the top and bottom rollers.

Locate the feeler gage on the flat of the roller next to the side plate of the assembly.

DETAIL A

BO LT "D"

RR5 OP TION SHOW N

Figure 34: Bead Roller Width Change

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CHAPTER 14 WIDTH CHANGE PROCEDURE

14. Rotate the top shaft from the 12:00 position toward the shear to decrease the

gap, or away from the shear to increase the gap until the feeler gage is captured.

15. Tighten the “C” bolt to lock the position of the shaft.

16. Repeat steps 11through 15for the remainder of the bead rollers.

17. Start the machine, jog the material through the bead assemblies and stop 2 to 3

inches from the entry shear dies.

18. Inspect the beads for depth and re-adjust as necessary.

CAUTION: SHUT THE MACHINE OFF BEFORE PROCEEDING.

19. Start the machine and jog the material through the bead assemblies and stop 2

to 3 inches from the entry shear dies

SHUT THE MACHINE OFF AGAIN BEFORE PROCEEDING.

20. Remove the two “C” bolts located in the slotted holes at the bottom edge of

the exit male shear die assembly and set the bolts and assembly aside. (Figure

35)

21. Remove the two “C” bolts in the slotted holes on the entry male shear die

assembly.

Figure 35: Shear Bolts

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CHAPTER 14 WIDTH CHANGE PROCEDURE

22. Visually site through the male entry die and rough align it to the forming tool

“line of fire” by sliding it left or right. Re-install the two “C” bolts into holes that correspond to the slots. Do not tighten the bolts at this time, just snug them up.

23. Install the male exit die in the same manner aligning it to the entry die and

again, just snug the bolts.

24. Start the machine and carefully jog the panel up to the shear. Check to see if

the panel will pass through the entry shear die. If not FIRST SHUT THE MACHINE OFF, then move the entry die so that the panel will pass through

it. Adjust the entry die so that it is as close to the outside vertical portion of the leg as possible without touching it. Once this is done, tighten the two “C” bolts on the entry male shear die assembly.

25. Check the exit shear die to ensure that the material will pass through it. If not

adjust as necessary.

26. Start the machine again and slowly jog the panel approximately 6” past the

exit male shear die assembly and stop. Again, TURN THE MACHINE OFF.

27. Adjust the exit male shear die assembly so that it is offset to the outside of the

entry die by approximately 1/64” and lock down the two “C” bolts (Figure 36)

This offset is necessary so that after a cut is made, the leading edge of the

panel does not hang up on the exit die.

28. Look down the leg of the panel and make sure that the entry and exit male

shear die assemblies are not touching the panel as it passes through them.

Figure 36: Exit Die Adjustment

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CHAPTER 14 WIDTH CHANGE PROCEDURE

29. Make sure that one of the points of the top shear blade is inboard of the

vertical portion of the male leg. This part of the leg should be cut with the

angle or rake of the blade to cut in a scissor action against the vertical die. See

TOP SHEAR BLADE ADJUSTMENT (Figure 19 & Figure 20) if

adjustment is necessary.

30. Start the machine and press the shear down button to cut off the panel, then

jog the material through the shear again and stop.

31. Inspect the two cuts and adjust the dies as necessary until an acceptable cut is

made. Again, TURN THE MACHINE OFF BEFORE MAKING ANY

ADJUSTMENTS.

32. Once you are satisfied with the cut being made, you are ready to run panel.

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

PROFILE CHANGEOVER PROCEDURE

1. Remove Top Covers number 1, 2, 3, 4, and 5 (Figure 37) and set aside.

Figure 37: Remove Top Covers

2. Using a ½” wrench, remove the bolts holding the right and left Tooling Rails to

the Fixed Rail Mounts (Figure 38). Store the tooling and set the hardware near the machine for use when installing the next profile. Note: the SS100, SS150, SS450/450SL, and BP profiles all share the same left-side rollers, so if you are changing from one of these profiles to another you will only need to remove the right-side Tooling Rails. Likewise, the FF100 and FF150 profiles also share the same left-side rollers, so if you are changing between these two profiles you will only need to remove the right-side Tooling Rails.

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 38: Removing Tooling Rails

3. Refer to the SSQ Slide Block chart (Figure 39) and find the profile you will be

installing into the machine. It will tell you if the Right Side Fixed Mount Rail #1 needs to be in the Inboard position or Outboard position (Figure 40).

IF THE RAIL IS NOT IN THE CORRECT POSITION, GO TO STEP 4. IF THE RAIL IS IN THE CORRECT POSITION GO TO STEP 6.

SSQ SLIDE BLOCK CHART

PROFILE

BP, FF100, SS100, SS150 INBOARD

FF150, SS200, SS450, SS550, SS675 OUTBOARD

Figure 39: Block Chart

RIGHT SIDE FIXED

MOUNT RAIL #1

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 40: Inboard/Outboard Positions

Page 57

CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

4. Loosen bolt “C” on the first 4 Slide Block assemblies (Figure 41 or Figure 42).

Figure 41: April 2009 and later

Figure 42: Machines made before April 2009

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

5. Once all 4 bolts are loose, slide the Right Side Fixed Mount Rail #1 to the correct

position (Figure 43), either “inboard” or “outboard". Make sure that it is fully in position and then tighten the “C” bolts (Figure 41 or Figure 42).

Figure 43: Right Side Fixed Mount Rail

6. Locate your profile in the chart below to see what position the Left Side Fixed

Mount Rail #1 needs to be in.

PROFILE

SS200/210A, SS550, SS675 POSITION "A", OUTBOARD

SS100, SS150, SS450, FF100, FF150, BP POSITION "B", INBOARD

Figure 44: Profile Chart

LEFT SIDE FIXED MOUNT

RAIL #1 POSITION

Now look at the machine to see what position the Left Side Fixed Mount Rail #1 is currently in. The stamped letter closest to the mounting bolts "C" indicates the position (Figure 46). If it is in the correct position proceed to Step 7, otherwise, loosen the four mounting bolts "C", slide the Left Side Fixed Mount Rail #1 as far as it will go in either the "inboard" or "outboard" direction, and re-tighten the bolts.

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 45: Left Side Fixed Mount Rail

7. Find the R1 Tooling Rail and set it flat on top of the Right Side Fixed Mount Rail

#1 making sure the correct number shows in Sight Hole “C” (Figure 47). Thread the two mounting bolts into the slots of the rail and finger-tighten them. Pull the Tooling Rail assembly toward the outside of the machine until the two Tooling Rail Spacers “D” contact the face of the Fixed Mount Rail. Hold it in place while tightening the mounting bolts with a ½” wrench.

Figure 46: Shown in the “A” position

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 47: Tooling Rail Identification

Figure 48: R1 Tooling Rail Spacers

8. Continue installing the remainder of the right and left tooling rails in sequence as

described above.

Special Instructions for the SS100, SS150, SS450, and BP Profiles:

The Left #1 Tooling Rail Assembly (L1-1) for these profiles can be mounted

in one of two possible positions based on the required height of the male leg.

When mounting this Tooling Rail Assembly for use with the SS150 or BP

1½" profiles pull it toward the outside of the machine until the two Tooling

Rail Spacers “D” contact the face of the Left Side Fixed Mount Rail #1

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

(Figure 49). When mounting the Tooling Rail Assembly for use with the

SS100, SS450, or BP 1" profiles push it toward the center of the machine

until the Tooling Rail Backstops "E" contact the Left Side Fixed Mount Rail

#1 (Figure 49). Once it is positioned properly, tighten the two Mounting Bolts

"F" using a 1/2" wrench.

Figure 49: L1-1 Special Instructions

9. Loosen the two “A” Bolts on the Right Entry Guide (Figure 50). Slide the entry

guide to the left or right until the alignment pin, located on the end of the top shoe of the entry guide, is directly under one of the notches on the Tooling Rail Marker Plate. Make sure to choose the notch that corresponds to the desired leg configuration as noted on the decal on the top of the marker plate.

10. Once the Right Entry Guide is in the correct position, tighten the two “A” bolts.

11. Loosen the two “A” bolts on the Left Entry Guide (Figure 50).

12. Slide the entry guide to the left or right to accept the new coil width. Make sure

that the coil is captured snugly between the entry guides and re-tighten the two “A” bolts.

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 50: Entry Guide Alignment Notches and Pins

13. Using the Tooling Rail Adjustment Handle (Figure 51), align the notch on the

tooling rail marker plate to the alignment pin (Figure 25 on page 38) located in the Left Entry Guide. Make sure to choose the notch that corresponds to the desired leg configuration as noted on the decal on the marker plate. Turning the handle clockwise moves the tooling out-ward, turning it counter-clockwise moves move it in-ward.

Figure 51: Tooling Rail Adjustment Handle

14. Load material onto the Expandable Arbor and align it to the correct position

(Figure 10).

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 52: Marker Plate Notch and Pin

15. Load the reeled coil onto the machine using a fork lift or other rated lifting device.

16. Cut a 1” triangle of material off the 2 leading corners of the coil and feed it into

the entry guides.

Figure 53: Preparing Coil for Loading

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

17. Start the machine and use the Jog button on the Manual Control Box or Computer

to jog the material through the machine 6 to 8 inches at a time until it exits the last forming stations, and is about 1” from the Bead Roller Assembly (Figure 54).

Figure 54: Jogging Material thru Machine

IF YOU NEED BEADS IN THE PANEL, GO TO STEP 18

IF YOU DO NOT NEED BEADS IN THE PANEL, GO TO STEP 21.

18. If you require beads in the panel, determine the spacing needed. For Example: a

12” wide panel with 2 beads centered on the panel would give you 3 equal spaces or 12” divided by 3, which equals 4” from center to center of each bead. Hook the end of your tape measure on the outside bottom corner of the female leg. Use a magic marker or grease pencil to mark the 4” and 8” locations on the panel. You now have 3 equal spaces. (Figure 55)

Figure 55: Spacing Bead Rollers

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

19. Loosen the Slide Lock Bolts “D” on the top and bottom bead assemblies

(Figure 21) and slide each bottom and top roll assembly left or right to center them on the 4” and 8” marks on the panel.

20. Lock the two top bead assemblies in the correct position by tightening the “D”

bolt on each assembly (Figure 21). Next align the bottom bead rollers to the tops so that the ends of the top and bottom rollers are flush with each other and tighten the bottom “D” bolts on these 2 assemblies.

21. Using a 7/16” wrench, remove the Shear Cover and set aside.

Figure 56: Removing Shear Cover

22. Remove the two “C” bolts on the exit male and female shear die assemblies

located in the slotted holes at the bottom edge of the die holder (Figure 57). Store the shear dies with the profile you just removed, and set the bolts aside for use when installing the new shear dies.

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

Figure 57: Remove Shear Bolts

23. Remove the two “C” bolts from the slotted holes on the entry male and female

shear die assemblies as described previously.

24. Locate the shear dies that correspond to the profile you have just installed.

Separate the male and female entry and exit shear dies.

25. Set the Male Entry Die on top of the Bottom Die (Figure 20 - Detail A on page

32). Visually sight through the male entry die and roughly align it to the forming tool “line of fire” by sliding it left or right. Re-install the two “C” bolts into the holes that correspond to the slots. Do not tighten the bolts at this time, just snug them up.

26. Install the male exit die in the same manner aligning it to the entry die and again,

just snug the bolts.

27. Repeat steps 23 through 26 for the Female Dies.

28. Start the machine and carefully jog the panel up to the shear. Check to see if the

panel will pass through the entry male and female shear dies. If not, FIRST SHUT THE MACHINE OFF, then move the male and/or female entry dies so

that the panel will pass through them. Adjust the entry die so that it is as close to the outside vertical portion of the leg as possible without touching it. Once this is done, tighten the two “C” bolts on these assemblies.

29. Check the exit male and female shear dies to ensure that the material will pass

through them. If not, adjust as necessary.

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CHAPTER 15 PROFILE CHANGEOVER PROCEDURE

30. Start the machine again and slowly jog the panel approximately 6” past the exit

die and stop. Again, TURN THE MACHINE OFF.

31. Adjust the male and female exit dies so that they are offset to the outside of the

entry die by approximately 1/64” and lock down the two “C” bolts (Figure 58) on each assembly. This offset is necessary so that after a cut is made, the leading edge of the panel does not hang up on the exit die.

Figure 58: Exit Die Adjustment

32. Look down the leg of the panel and make sure that the entry and exit dies are not

touching the panel as it passes through them.

33. Start the machine and press the shear down button to cut off the panel, then jog

the material through the shear approximately 2” and stop.

34. Inspect the two cuts and adjust the dies as necessary until an acceptable cut is

achieved. Again, TURN THE MACHINE OFF BEFORE MAKING ANY

ADJUSTMENTS! NEVER REACH THROUGH THE SHEAR WHILE THE MACHINE IS RUNNING. SERIOUS INJURY COULD RESULT!

35. Once the cut is acceptable, you are ready to start panel production.

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