SSH Roof Panel Machine Manual

CHAPTER 14

CHAPTER 15

CHAPTER 16

CHAPTER 17

APPENDIX A

APPENDIX B

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

TABLE OF CONTENTS

SPECIFICATIONS .......................................................................................... 3

PRECAUTIONS .............................................................................................. 4

MACHINE ORIENTATION ........................................................................... 5

GENERAL MAINTENANCE ......................................................................... 7

Recommended Lubricants and Fluids...................................................... 8

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 ........................................................................................... 25

SHEAR ASSEMBLY .................................................................................... 29

BEAD AND STRIATION ROLLER ASSEMBLY ...................................... 33

CLIP RELIEF ROLLER ASSEMBLY .......................................................... 35

ENTRY DRUM ASSEMBLY ....................................................................... 36

WIDTH AND PROFILE CHANGE PROCEDURE ..................................... 37

Tooling Changeover .............................................................................. 37

Entry Guide Adjustment ........................................................................ 40

Tooling Rail to Entry Guide Alignment ................................................ 42

Shear Changeover .................................................................................. 42

Loading Machine with Material ............................................................ 42

Bead Rollers (if equipped) ..................................................................... 44

Shear Alignment .................................................................................... 44

RUN OUT TABLES AND REMOTE LIMIT SWITCH ............................... 46

QUICK CHANGE POWER PAC (QCPP) .................................................... 49

TROUBLESHOOTING ................................................................................. 50

ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS ...................... 54

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

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

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

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

LIST OF FIGURES

Figure 1: Machine Orientation ....................................................................................................... 5

Figure 2: Mounting Foot Detail ..................................................................................................... 6

Figure 3: Controls ........................................................................................................................ 12

Figure 4: Main Control Cable ...................................................................................................... 13

Figure 5: Run Out Table and Remote Limit Switch .................................................................... 14

Figure 6: Main Control Box Fuse ................................................................................................ 15

Figure 7: QCPP E 1-6 Fuse Location .......................................................................................... 15

Figure 8: Expandable Arbor Set-Up ............................................................................................ 17

Figure 9: Expandable Reel Assembly .......................................................................................... 19

Figure 10: Material Routing......................................................................................................... 21

Figure 11: Hydraulic System Overview ...................................................................................... 23

Figure 12: Hydraulic System – Details ........................................................................................ 24

Figure 13: Hydraulic Fluid Level ................................................................................................ 24

Figure 14: Drive Roll Assembly .................................................................................................. 26

Figure 15: Sprockets and Shafts .................................................................................................. 27

Figure 16: Upper and Lower Chains ............................................................................................ 28

Figure 17: Entry/Exit Views ........................................................................................................ 30

Figure 18: Shear Die Detail Views .............................................................................................. 31

Figure 19: Bead Roller Assembly ................................................................................................ 34

Figure 20: Clip Relief Roller Assembly ...................................................................................... 35

Figure 21: Entry Drum ................................................................................................................. 36

Figure 22: Remove Covers .......................................................................................................... 38

Figure 23: Tooling Rail Detail ..................................................................................................... 39

Figure 24: Entry Guide ................................................................................................................ 41

Figure 25: Feeding Material into Entry Guides ........................................................................... 43

Figure 26: Material Entering Bead Rollers .................................................................................. 43

Figure 27: Exit Die Adjustment ................................................................................................... 45

Figure 28: Run Out Table ............................................................................................................ 47

Figure 29: Run Out Table Setup .................................................................................................. 48

Figure 30: Quick Change Power Pac Fasteners ........................................................................... 49

Figure 31: Bottom of Stroke Limit Switch .................................................................................. 50

Figure 32: Top of Stroke Limit Switch ........................................................................................ 52

Figure 33: Limit Switch Adjustment Screws ............................................................................... 52

Figure 34: SSH100 Roller System ............................................................................................... 54

Figure 35: SS100 Panel Profile .................................................................................................... 55

Figure 36: SSH150 Roller System ............................................................................................... 56


Figure 38: SSH450/450SL Roller System ................................................................................... 58


Figure 40: SS450SL Panel Profile ............................................................................................... 60

Figure 41: FFH100 Roller System ............................................................................................... 61

Figure 42: FF100 Panel Profile .................................................................................................... 62

Figure 43: FFH150 Roller System ............................................................................................... 63

Figure 44: FF150 Panel Profile .................................................................................................... 64

Figure 45: BP1 Roller System ..................................................................................................... 65

Figure 46: BP1 Panel Profile ....................................................................................................... 66

1

LIST OF FIGURES

Figure 47: BP15 Roller System ................................................................................................... 67

Figure 48: BP15 Panel Profile ..................................................................................................... 68

Figure 49: PLC Assembly .............................................................................................................. 1

Figure 50: Serial Number Plate ...................................................................................................... 1

Figure 51: Home Screen ................................................................................................................ 2

Figure 52: Job Entry Screen ........................................................................................................... 3

Figure 53: Specify Job to Run First ............................................................................................... 4

Figure 54: Auto-Run Screen .......................................................................................................... 4

Figure 55: Calibration Screen ........................................................................................................ 5



Figure 58: Setup Screen ................................................................................................................. 7

Figure 59: Status Screen ................................................................................................................ 7

Figure 60: Security Screen ............................................................................................................. 8

Figure 61: Coils Password Access Screen ..................................................................................... 9

Figure 62: Coils Screen .................................................................................................................. 9

Figure 63: Coil Indicator .............................................................................................................. 10

Figure 64: Coils Color Screen...................................................................................................... 11

Figure 65: Length Calculator Screen ........................................................................................... 11

Figure 66: Material and Thickness Screen ................................................................................... 12

Figure 67: Coil Dimensions ......................................................................................................... 12

2

CHAPTER 1

SSH SPECIFICATIONS

SPECIFICATIONS

SSH Dimensions: Length-12’ 10” (3.9m)

SSH on Trailer:

Length-17’ 6” (5.3m)

Speed:

(18m/min.) Approx.

Drive: Hydraulic via chain, sprocket and gear using 8 polyurethane drive rollers.

Shear:

Hydraulically powered, infinitely adjustable, hardened tool steel dies and blades w/panel recognition proximity sensor.

Hydraulic Fluid:

15 Gallons - 32AW

Coil Width

14” to 24” (356mm to 610mm) Note: 24” coil width requires

Expandable Arbor or Remote De-coiler Stand.

Materials Formed

Painted Steel

Painted Aluminum

Copper

26ga. to 24ga. (.5mm to .6mm)

Painted, Galvanized, Aluminized

.027” to .040” (.7mm to 1.0mm)

16 oz. to 20 oz. ¾ Hard

Controls

Standard: 12VDC Manual Control Box w/Length Control

Limit Switch

Optional: PLC or AMS Computer Batch and Length Control

3

CHAPTER 2

PRECAUTIONS

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.

4

CHAPTER 3

MACHINE ORIENTATION


Figure 1: Machine Orientation

5

CHAPTER 3


Figure 2: Mounting Foot Detail

6

CHAPTER 4

GENERAL MAINTENANCE


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 the machine with a tarp to protect it but provide good ventilation to prevent condensation and rust.

3. Keep the 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 the 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. Keep Entry Guide Carriage clean and lubricate as needed with Spray Lube.

8. Keep Bead Roller Carriage Shafts (Figure 19 on page 34) clean and lubricate with Spray

Lube.

9. Keep Arbor Cradles (Figure 9 on page 19) lubricated with Clear Grease.

10. Lubricate Arbor Nut (Figure 8 on page 17) using a grease gun with EP Grease when threads begin to look dry.

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

12. 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.

13. Lubricate both faces of the Shear Blades and Dies (Figure 17 on page 30) a minimum of once daily with Spray Lube. More should be added as needed before the cut edges begin to deteriorate.

7

CHAPTER 4


Recommended Lubricants and Fluids

Spray Lube for:

Shear Blades, Dies, Entry Guide, Bead Roller Carriage Shafts and chains

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

Catalog No. 31110

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:

Various Manufacturers

Hydraulic Fluid (32AW) for:

Hydraulic Tank

Available from:

Various Manufacturers

8

CHAPTER 5

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 being used 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 a 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:

(Figure 3 on page 12)

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, the machine will NOT run continuously in reverse.

B. JOG-RUN Switch

This selector switch allows the machine to run 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 the machine is ready to run.

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)

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)

This button acts as a cycle interrupt for the drive system. Pressing the Stop Feed

Button on either the entry or exit end of the machine will stop the machine drive system.

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 the shear back to the top or home position.

9

CHAPTER 5


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

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 return back to the top of stroke 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)

The Emergency Stop-Power On button must be pulled 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.

ENTRY END CONTROL STATION

A. JOG SWITCH

This switch is used to load coil into the machine. Turn the switch to the right to jog the material forward or turn the switch to the left to jog the material in reverse.

B. STOP FEED (Red button)

This button acts as a cycle interrupt for the drive system. Pressing the Stop Feed

Button on either the entry or exit end of the machine will stop the machine drive system.

MAIN CONTROL CABLE


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

10

CHAPTER 5


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.

REMOTE LIMIT SWITCH


Note: The 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 manual panel length control. The remote limit switch is designed to attach to the right side of the optional run-out tables. 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 intended 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 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. See section RUN OUT TABLES AND REMOTE LIMIT SWITCH on page 46.

FUSES


All machines, gas or electric powered, have a 10-amp time delay fuse on the back of the

Electrical Control Panel Assembly. This fuse protects the electrical components. If the fuse is blown, the machine will lose all functions except Motor Start. Access can be gained by removing the entry end right 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

ELECTRIC MOTOR MACHINES


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 top cover of the contactor box located toward the entry end on the left side. Access can be gained by removing the entry end 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.

11

CHAPTER 5


Figure 3: Controls

12

CHAPTER 5


Figure 4: Main Control Cable

13

CHAPTER 5


Figure 5: Run Out Table and Remote Limit Switch

14

CHAPTER 5


Figure 6: Main Control Box Fuse

Figure 7: QCPP E 1-6 Fuse Location

15

CHAPTER 6

REEL STANDS, REELS AND EXPANDABLE ARBORS


EXPANDABLE ARBOR


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 entry 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 cap 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" cap screws 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 entry 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 8 on page 17), find the “D” dimension that corresponds to the profile being used.

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)

16

CHAPTER 6


Figure 8: Expandable Arbor Set-Up

17

CHAPTER 6


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 arbor cradles on the reel rack. Keep the arbor cradles lubricated with clear grease to minimize wear. (Figure 9 on page 19)

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 Bar should be used to keep the coil from uncoiling too fast during the fabrication of panels. Apply just enough drag to keep coil tensioned.

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.

18

CHAPTER 6


Figure 9: Expandable Reel Assembly

19

CHAPTER 6


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 9 on page 19).

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 to route the material show in

Figure 10 then remove the lifting device.

3. Rotate the Hold Down Bars to the closed position and thread the handle onto the hold down bolt. If material is 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 material is loaded onto the Expandable Arbor, 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, using a strap or rope, secure the coil around the outside edges through the inside diameter to prevent the coil from telescoping

(Figure 8 on page 17).

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

20

CHAPTER 6


Figure 10: Material Routing

21

CHAPTER 7

HYDRAULIC SYSTEM AND SCHEMATIC

HYDRAULIC SYSTEMS

Maintenance


The hydraulic system in the machine is a very durable and reliable system, however, 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

4 Machine runs slow after continuous operation.

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

SOLUTION

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

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

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.

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 12 on page 24 and Figure 13 on page 24)

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 Hydraulic Tank Filler Cap and Filler Neck from the Hydraulic Tank.

2. Using a hand pump, remove the hydraulic oil from the Hydraulic Tank. Tip the entry end of the machine up so that the remaining oil runs to the filler end of the tank and hand pump the remaining oil from the tank.

3. Remove the existing Hydraulic Filter and replace with a new Hydraulic Filter.

4. Fill the tank with fresh 32 weight fluid until it is 5” below the top of the Filler Neck

(approximately 15 gal).

5. Replace the Filler Neck and Filler Cap.

6. Cycle the drive and shear circuits to ensure that there is no air in the hydraulic system.

22

CHAPTER 7


Figure 11: Hydraulic System Overview

23

CHAPTER 7


* Note: Machines manufactured after April 2013 do not have a pressure switch.

Figure 12: Hydraulic System – Details

Figure 13: Hydraulic Fluid Level

24

CHAPTER 8

DRIVE SYSTEM

DRIVE SYSTEM

(Figure 14, Figure 15, and Figure 16 on pages 26, 27 and 28)

The drive system in the machine consists of four top and four bottom polyurethane drive rollers.

They are connected together via chain and sprocket. 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 a drive sprocket connected to the top and bottom drive shafts.

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 24ga. though the machine without the need for adjustment. If adjustment becomes necessary due to slippage, 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.

The chain tensioner used on this machine are squeeze type that can be manually pressed together when additional chain tension is required. When tensioning any chains be sure and squeeze the tensioners at both ends of the chain in order to maintain an even gap along the tensioner bars.

3.

The chains used in this system are #50 Roller Chain at the drive sprocket and #41

Roller Chain between drive rolls. See Figure 16 on page 28 for chain locations and lengths if chain replacement is necessary.

4.

The polyurethane drive rollers require occasional cleaning. The need for cleaning will become evident when the drive rolls start leaving a stripe the width of the drive roller on the formed panels that is not easily removed. 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

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.

rollers.

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.

25

CHAPTER 8

DRIVE SYSTEM

Figure 14: Drive Roll Assembly

26

CHAPTER 8

DRIVE SYSTEM

Figure 15: Sprockets and Shafts

27

CHAPTER 8

DRIVE SYSTEM

Figure 16: Upper and Lower Chains

28

CHAPTER 9

SHEAR ASSEMBLY

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 18 on page 31)

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 AND ADJUSTING ENTRY AND EXIT SHEAR DIES

(Figure 17 and Figure 18 on pages 30 and 31)

The Entry and Exit Shear Dies are specific to each roller set and they may need to be changed when changing profiles.

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 two mounting holes are found 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

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

29

CHAPTER 9

SHEAR ASSEMBLY

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 17: Entry/Exit Views

30

CHAPTER 9

SHEAR ASSEMBLY

Figure 18: Shear Die Detail Views

31

CHAPTER 9

SHEAR ASSEMBLY

TOP SHEAR BLADE ADJUSTMENT

(Figure 17 and Figure 18 – Details B and C on pages 30 and 31)

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. There should be 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

32

CHAPTER 10

BEAD AND STRIATION ROLLER ASSEMBLY



1.

The Bead / Striation Roller assembly 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.

4.

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 access is gained to the top slide lock-down screws,

SHUT OFF THE MACHINE AND DISCONNECT THE POWER BEFORE

CONTINUING.

5.

Loosen the top slide lock-down 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 the panel. Re-tighten screws

“C”.

6.

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

33

CHAPTER 10


Figure 19: Bead Roller Assembly

34

CHAPTER 11

CLIP RELIEF ROLLER ASSEMBLY

CLIP RELIEF ROLLER ASSEMBLY


1. Clip Relief Rollers 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 the machine (Figure

34 to Figure 48 on pages 54 to 68).

Note the location of clip relief assembly’s on left and right tooling rails, and locate them on the tooling set in the 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 20: Clip Relief Roller Assembly

35

CHAPTER 12

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 the material to be routed around the drums to get the painted side of the coil on the top as it enters 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.

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 a changing profiles, it may be necessary to move all three drums using the same procedure described above.

Figure 21: Entry Drum

36

CHAPTER 13

PROFILE CHANGEOVER PROCEDURE

WIDTH AND PROFILE CHANGE PROCEDURE

The profile changeover procedure consists of removing the tooling assemblies and shear dies from the machine, replacing them with another set and realigning the rails and shear dies. A change in coil width can also be done at this time. The following procedure will be a guide through this process.

CAUTION: Always make sure the 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.

Tooling Changeover


Tooling rails are stamped with an ” L” or” R” for installation on the left or right side, and with a profile number and sequence number. For example a rail stamped SS4-#1 R would be the number one right tooling rail for the SS450 profile.

1.

Disengage top cover latches on #1, #2, and #3 top covers. Remove and set aside.

2.

Remove Shear Cover and set aside.

3.

Locate and remove the “A” bolts on the left tooling rail #1. Remove rail and set it aside.

4.

Using the same procedure as above remove the remaining left and right tooling rails and set them aside for storage.

5.

Locate #1 right tooling rail of the profile to be installed.

6.

Carefully lower it into the machine and set it on the right carriage slide #1.

7.

Align the tooling mounting holes “A” and start one “A” bolt into threaded hole beneath.

Snug this bolt enough to hold tooling in place but DO NOT TIGHTEN. Align second hole and start bolt into threaded hole beneath.

8.

Tighten “A” bolts.

9.

Locate remaining right tooling rails #2, #3 etc. and install in the same manner as above.

10. Repeat the above procedures on the left side of the machine until all tooling rails are installed.

37

CHAPTER 13


Figure 22: Remove Covers

38

CHAPTER 13


Figure 23: Tooling Rail Detail

39

CHAPTER 13


Entry Guide Adjustment


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.

To align, loosen the “B” Bolt on the Right Entry Guide. Slide the entry guide to the left or right until DIM “C” is in the correct position that corresponds to the desired leg configuration as noted on Figure 24

2.

Retighten the “B” bolt.

3.

Loosen bolt “B” on the Left Entry Guide.

4.

Cut a 12” long piece of gage material from the coil that will be used.

5.

Slide gage material between the left and right entry guides.

6.

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 “B” bolt.

40

CHAPTER 13


Figure 24: Entry Guide

41

CHAPTER 13


Tooling Rail to Entry Guide Alignment


The #1 tooling rails are adjusted in and out on the slide carriages to line up to the entry guides.

The #2 tooling rails are adjusted in and out to line up with the #1 tooling rails. Finally, the #3 tooling rails are adjusted in and out to line up with the #2 tooling rails. If the tooling is not adjusted correctly the material will not be fed into the forming rollers properly.

1.

Loosen the two slide lock bolts “D” on right carriage slide # 1.

2.

Move Right Carriage Slide # 1 into position using the side of the right entry guide and the scale on the marker plate to set the correct “A dimension as shown on corresponding tooling rail set up chart.

3.

Repeat the above procedure for the left carriage slide # 1 using the correct “B” dimension on tooling rail set up chart.

4.

Align the # 2 and #3 Left and Right Carriage Slides by loosening the two “D” slide lock bolts on each rail. If there is a spacer bolted to the side of the previous rail, align the carriage rail flush to the spacer. If not, align the rails flush with each other.

5.

Proceed with each rail in succession from #1 to # 2 to #3, right and left as stated above

Shear Changeover


There are four shear die holders (female entry and exit and male entry and exit). The dies must be removed, replaced and re-aligned utilizing the shear dies for the new profile.

1.

Locate and remove two “C” bolts on exit female die holder. Set die holder aside.

2.

Repeat the above procedure for entry female die holder and male exit/ entry die holders.

Set all four-die holders aside to storage.

3.

Locate the four die holders corresponding to the profile that was just installed into the machine. Install the new die holders with the “C” bolts but do not tighten as the shear should be adjusted with material fed into the machine.

Loading Machine with Material

1.

Load material onto the Expandable Arbor and align it to the correct position using the chart on Figure 8 on page 17.

Note: Also see REEL STANDS, REELS AND EXPANDABLE ARBORS on page 16 for more information.

2.

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 on Figure 10 on page 21.

3.

Cut a 1” triangle off of the 2 leading corners of the coil and feed it into the entry guides as shown in Figure 25 on page 43.

42

CHAPTER 13


Figure 25: Feeding Material into Entry Guides

4.

Start the machine and use the Jog button on the manual control box or computer controller to jog the material through the machine 6 to 8 inches at a time until it exits the last forming stations and the leading edge is about 1” from the Bead Roller Assembly (if equipped).

SHUT THE MACHINE DOWN BEFORE PROCEEDING.

Figure 26: Material Entering Bead Rollers

43

CHAPTER 13


Bead Rollers (if equipped)


If the machine is equipped with a bead roller option and the panel requires beads to be on the panel, use the following procedure to adjust the bead rollers.

1.

Determine the spacing needed. For Example: a 12” wide panel with 2 beads centered on the panel would need 3 equal spaces or 12” divided by 3 equals 4” from center to center of each bead. Hook the end of the 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. There are now 3 equal spaces.

2.

Loosen Bolts “D” on the top and bottom bead assemblies and slide each bottom and top roll assembly left or right to center them on the marks on the panel made in the previous step.

3.

Lock the 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.

4.

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.

5.

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

6.

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.

7.

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.

8.

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

9.

Start the machine, jog the material through the bead assemblies and stop 2 to 3 inches from the entry shear dies.

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

11. 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.

Shear Alignment


With material loaded in the machine and stopped before it gets to the shears, use the following procedure to adjust the shear dies in order to cut the material.

1. 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.

2.

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

44

CHAPTER 13


3.

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.

4.

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 27 on page 45) 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 27: Exit Die Adjustment

5.

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.

6.

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.

7.

Start the machine and press the shear down button to cut off the panel, then jog the material through the shear again and stop.

8.

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

SHEAR ASSEMBLY section on page 29 for more information.

TURN THE MACHINE OFF BEFORE MAKING ANY ADJUSTMENTS.

9.

Once a satisfactory cut has been made then the machine is ready to run panels.

45

CHAPTER 14

RUN OUT TABLES AND REMOTE LIMIT SWITCH



The Run-Out Table attaches to the Exit End of the Shear assembly, and is used to support the panel as it exits the machine. It is available in 10 ft. long sections that fasten together, and have adjustable legs so they can be set to the correct height. The Remote Limit Switch (Figure 5 on page 14) is designed to be used with the run out tables for controlling panel length.

1.

Set the first Run-Out Table on its side and in front of the machine with the leg assembly away from the shear.

2. Open the leg assembly and set it upright on the ground.

3. Lift the attachment end of the table and drop it over the 2 threaded bolts on the Shear Run-

Out Table Bracket.

4. Loosen the 2 knob-handles on the leg assembly and allow the legs to fall free. Sight the height of the table on the left and right side adjusting it level to the machine using the knob-handles to lock the legs in place. See Figure 29 on page 48 for correct and incorrect set up and details.

5. Repeat the above procedures for each succeeding table and attach it to the bracket on the end of the previous table.

46

CHAPTER 14


Figure 28: Run Out Table

47

CHAPTER 14


Figure 29: Run Out Table Setup

48

CHAPTER 15

QUICK CHANGE POWER PAC

QUICK CHANGE POWER PAC (QCPP)

(Figure 30 and on pages 49)

The Quick Change Power Pac allows the machine to change from one power source to another very quickly. For example, it is useful to run the machine at the jobsite with a gas engine and use it in a factory or indoor setting with an electric motor as well. It requires two people to lift the

Power Pac out of and into the machine. To change the power pac see below.

POWER PAC REMOVAL

1. Remove the screws holding the Left Cover on the machine. Set cover aside.

2. Separate the Male /Female Connectors of the Main Communication Cable by unscrewing them from each other.

3. Using a 9/16” wrench, remove the two 3/8” bolts ("A") connecting the hydraulic pump to the motor-pump adapter and set aside for later use.

4. Un-couple the pump from the adapter as well as the coupling insert found in the pump adapter.

5. Using a 9/16” wrench, remove the two 3/8” bolts ("B") connecting the Power Pac to the machine frame.

6. Using the two handles, lift the Quick Change Power Pac out of the machine and set it aside.

Install new Power Pac in reverse order.

Figure 30: Quick Change Power Pac Fasteners

49

CHAPTER 16

TROUBLESHOOTING

TROUBLESHOOTING

The hydraulic system operates the Shear and Drive assemblies. They are interfaced together and electronically activated. The hydraulic system pressure is factory set at 2000 psi and should not be changed. Some of the common problems that occur and their solutions follow below.

1. Shear travels to the bottom of the stroke and does not return to the top of the stroke.

The hydraulic system can be heard laboring and pushing the Red Shear Up Button does not return it to the top of stroke.

SOLUTION for machines manufactured before April 2013 with an adjustable pressure switch: Adjust the pressure switch (Figure 12 on page 24) by turning the silver knurled sleeve counterclockwise until the shear goes up. Note: If the sleeve is turned too far CCW, problem #2 below will be shown on the next cut made.

SOLUTION for machines manufactured after April 2013 with an adjustable limit switch:

Loosen Screws “A” (Figure 31). Press Shear Down. While the hydraulic system is laboring and the shear is stuck in the lower position, raise the Bottom of Stroke

Limit switch until it clicks and the Shear goes up. Tighten Screws “A”. Note: If the limit switch is adjusted too far up, problem #2, below, will be seen on the next cut made.

Figure 31: Bottom of Stroke Limit Switch

50

CHAPTER 16

TROUBLESHOOTING

2. Shear travels to the bottom of the stroke and returns to the top of the stroke without cutting the panel completely through.

SOLUTION for machines manufactured before April 2013 with an adjustable pressure switch: Press and hold the Green Shear Down Button until the panel is cut off.

Remove the cut panel and jog material out 2 or 3 inches past the shear. Adjust the pressure switch (Figure 12 on page 24) by turning the silver knurled sleeve “A” clockwise 1/8 of a turn. Press the Shear Down Button again. Check to see if the panel is cut off completely. If not, repeat this procedure until the cut is made with one stroke of the shear. Note: If the sleeve is turned too far CW, problem #1 above will be shown on the next cut made.

SOLUTION for machines manufactured after April 2013 with an adjustable limit switch:

Loosen Screws “A” (Figure 31). Lower the Bottom of Stroke Limit Switch.

Tighten Screws “A”. Press the Shear Down button and repeat adjustment if necessary. Note: If the limit switch is adjusted too far down, problem #1, above, will be seen on the next cut made.

3. Shear is at the top of the stroke, the hydraulic system can be heard laboring and the next panel cannot be run.

SOLUTION: Remove the Shear Cover. Note the 2 Limit Switch Arms “A” (Figure 32 on page 52). Lift the arms one at a time. If one of them stops the hydraulic system laboring then that Limit Switch arm needs to be adjusted. If neither of them stops it, lift both arms at the same time to see if it stops. If it does then both arms need adjusting.

ADJUSTMENT: Loosen socket cap screws “C” (Figure 33 on page 52). Move limit switch down until a click is heard. Tighten socket cap screws “C”. Adjust one or both sides as required from test above. Start the engine. If the adjustment/adjustments were done correctly, the hydraulic system should no longer be laboring and the next panel can be run.

51

CHAPTER 16

TROUBLESHOOTING

Figure 32: Top of Stroke Limit Switch

Figure 33: Limit Switch Adjustment Screws

52

CHAPTER 16

TROUBLESHOOTING

4. After making a cut, the male or female leg of the next panel gets caught on the exit shear die and damages the panel.

SOLUTION: This problem normally shows up after making a roller system/shear die change. The entry dies both male and female should be as close to the vertical leg of the panel as possible without touching. Once this is achieved, the exit die should be set just outside the vertical leg of the entry die so that as the fresh cut edge of the panel passes by the exit die it doesn’t getting caught (Figure 18 on page 31).

5. The male and or female leg gets crushed when shearing.

SOLUTION #1: Check the Shear Blades directly over the male and female legs to make sure that the points of the blades are in the correct position (Figure 17 and Figure

18 on pages 30 and 31).

SOLUTION #2: Make sure that the shear blades and dies are well lubricated on both sides with the proper lubricant (See GENERAL MAINTENANCE on page 7).

6. Manual Control Panel buttons do not work.

SOLUTION #1: Check fuse inside of Manual Control Box. Replace if blown with a 10amp fuse (Figure 6 on page 15).

SOLUTION #2: If the machine is powered by a gas engine, check the condition of the battery. The control system requires 12 volts to operate properly. Replace or charge battery as required.

SOLUTION #3: Make sure that the Main Control Cable (Figure 4 on page 13) is properly connected to the connector on the front of the Control Panel.

53

CHAPTER 17

ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS


Figure 34: SSH100 Roller System

54

CHAPTER 17


Figure 35: SS100 Panel Profile

55

CHAPTER 17


Figure 36: SSH150 Roller System

56

CHAPTER 17



57

CHAPTER 17


Figure 38: SSH450/450SL Roller System

58

CHAPTER 17



59

CHAPTER 17


Figure 40: SS450SL Panel Profile

60

CHAPTER 17


Figure 41: FFH100 Roller System

61

CHAPTER 17


Figure 42: FF100 Panel Profile

62

CHAPTER 17


Figure 43: FFH150 Roller System

63

CHAPTER 17


Figure 44: FF150 Panel Profile

64

CHAPTER 17


Figure 45: BP1 Roller System

65

CHAPTER 17


Figure 46: BP1 Panel Profile

66

CHAPTER 17


Figure 47: BP15 Roller System

67

CHAPTER 17


Figure 48: BP15 Panel Profile

68

APPENDIX A

PLC CONTROLLER

PLC CONTROLLER

Figure 49: PLC Assembly

Figure 50: Serial Number Plate

A - 1

APPENDIX A

PLC CONTROLLER

Home

When the controller is turned on, it will automatically go to the home screen.

Figure 51: Home Screen

Manual Operation

The machine can be manually operated from the home screen by pressing the Jog and

Shear buttons.

JOG:

FWD and REV JOG buttons will jog the machine forward and reverse as long as the button is depressed. When the JOG buttons are released, the action will stop. The FWD and REV MICRO buttons will jog the material approximately ¼" each time the button is pressed.

SHEAR:

The shear UP and DOWN buttons are momentary and will act in a similar manner as the jog buttons. The SHEAR CYCLE button only needs to be pressed once and the shear will go to the bottom of the stroke and back up to the top. At any time during the shearing cycle, the UP button on the display or red stop button next to the screen can be pressed to return the shear to the top. CAUTION: The shear will stop without returning to the top if the E-Stop pushbutton on the manual control box below the PLC is pressed.

This button shuts off all power to the machine and machine controls. Upon start-up, the shear will return to the top.

Automatic Operation

The pre-run sequence must be completed in the correct order before automatic operation can be utilized.

A - 2

APPENDIX A

PLC CONTROLLER

Pre-Run Sequence:

1. Jog the material forward using the manual FWD JOG or MICRO buttons on the Home screen or the JOG switch at the entry end of the machine.

The material must exit the shear and be detected by the panel detection sensor.

2. Shear the material using the Shear Cycle button. At that point, the machine will be fully loaded with material, the length counter will be reset and the controller will be ready to run in automatic mode.

If the machine goes forward or reverse and the encoder does not detect movement, the pre-run sequence will be reset and the controller will not run in automatic mode. This would happen if the material was cut at the entry end of the machine at the end of a job or at the end of a coil. This could also happen if the encoder did not have proper tension on the material.

Job Entry

Jobs can be programmed to run automatically. From the Home screen, press the Job

Entry button to enter the Job Entry Screen.

Figure 52: Job Entry Screen

Programming Jobs

The controller can store up to ninety nine jobs or lengths, called: Job Numbers. Press the

Previous and the Next buttons to change the Job Number. The Job Number display is also an input in order to skip many jobs at a time. Press the Job Number display and enter the desired job number to program or run.

Enter in the quantity of parts to run and the length of the part.

Specify if the machine will pause at the end of job. If Yes is selected, the machine will stop after the job is done running. The user can then press Start to run the next job or return to the Job Entry. If No is selected, the machine will run the current job and automatically start running the next job. If yes is selected and there is no job

A - 3

APPENDIX A

PLC CONTROLLER

programmed after the current job, the controller will stop and return to the Job Entry screen.

Clear Jobs

To clear the current job on the screen press Clear Job. To clear all the jobs in the controller, press Clear All. The next screen will confirm the Clear All command, press

Yes to clear all jobs.

Auto Run

Press the Run Mode button to run the jobs that are programmed. Type in the job number to run first (if different than the job that was just programmed).

Figure 53: Specify Job to Run First

Then hit Enter to continue to the Auto-Run mode.

Figure 54: Auto-Run Screen

A - 4

APPENDIX A

Automatic Operation

PLC CONTROLLER

In the Auto Run screen, the current job and progress are displayed. Press the Start button to begin running the job. When the current job is complete the next job will start if the No button for pause was pressed for the current job. If the Yes button was pressed for pause or if there is no next job programmed, the controller will return to the Job Entry screen after the current job is completed.

On the Fly Calibration

The controller can be calibrated at any time while the machine is running to improve accuracy of the parts being run. If the machine is consistently making parts too short or too long, press Stop & Calibrate to bring up the Calibration screen.

Figure 55: Calibration Screen

The length of the last part will automatically populate to the length that the controller

‘thought’ was run. Measure the length of the part, enter in the actual measured length and press Enter to re-calibrate the controller. Or press cancel to return to the Auto-Run screen. Press Start on the Auto-Run screen to continue operation.

Calibration

The controller can also be calibrated from the Home screen by pressing the Calibrate button. On the calibration screen, enter in the desired part length to use to calibrate the controller. A length of over 12” is required and a length of 36” or more is recommended.

Press the Start button to run the specified part.

A - 5

APPENDIX A

PLC CONTROLLER


The controller will display the theoretical length of the part after it is produced. The theoretical length may be slightly different than the intended calibration length due.

Measure the length of the part and input the length in the Actual Measured Length fields.

Press Enter to re-calibrate the controller or Cancel to return to the Home screen without making any changes to the controller.


Setup:

From the Home screen, press the Setup button to make setting changes to the controller.

A - 6

APPENDIX A

PLC CONTROLLER

Figure 58: Setup Screen

In the Setup screen, the Units of Measure can be changed to Imperial units in either feet and inches (ft/in) or only inches (in) or Metric units (mm).

Example: ft/in: 10’ 4 1/16” mm: 3,151mm

The shear operation can be turned on and off if an auxiliary shear such as the Swenson

Snap Table will be utilized.

The brightness of the display can also be adjusted up or down by pressing the right and left arrow buttons.

Status/Diagnostics:

In order to help troubleshoot the machine, press the Status button found in on the setup screen to bring up the status of the machine as seen from the controller.

Figure 59: Status Screen

A - 7

APPENDIX A

PLC CONTROLLER

The Status 1 screen shows the condition of the Hydraulic Pressure Switch and the Top of

Stroke Limit Switch. If one or both of the TOS Shear Limit Switches are not activated the TOS Shear Limit Switch light will be on. Refer to the Shear section in the machine manual for limit switch adjustment.

If the motor is not on or if the pressure switch is not activated then the Hydraulic Motor light will be on.

The Status screen lists the Encoder Wheel Circumference. This value is changed automatically when the controller is calibrated. The Stop Reaction Distance is also automatically changed by the controller as the machine runs. In order to reset these values, press the Restore Defaults button. NOTE: Calibration should be initiated following the defaults restore. The Total Material Ran through the machine with the controller on is shown on this screen. The Total Material Ran can be reset by pressing the Reset button. If the security is turned on, the password will be required to reset the

Total Material Ran.

Press Back to return to the Setup Screen.

Security:

From the Setup screen press the Security Settings button to enter the security screen. The default password is: 1234.

Figure 60: Security Screen

If the security is turned on, the password will be required to change the stored coil lengths and colors or to reset the Total Material Ran value (totalizer). If security is turned off, no password is needed to make changes to these values. With security turned off the

Security screen displays the current password which can be changed by entering a new password and pressing the enter button. Once this is done, the new password will be needed to make any changes to the coil lengths and colors or to reset the Total Material

Ran.

A - 8

APPENDIX A

PLC CONTROLLER

Coil Tracking:

From the Home screen, press the Coils button to change the coil of material to track. If the security is turned on, a password must be entered if changes to the stored coils are necessary. If security is turned off, the controller will display the current coil screen and changes can be made without the password.

Figure 61: Coils Password Access Screen

Without the password, press Continue to view the Coils screen.

Figure 62: Coils Screen

The controller has the ability to track the length of three different coils of material. Press

Coil #1, 2 or 3 to change the coil to be run through the machine. When a new coil is purchased, press the Purchased Length numerical display to input the length of the coil into the controller. The Remaining Length will reset to the new purchased length. As material is run through the machine, the controller will subtract material from the remaining length. The coil (#1, 2 or 3) that is displayed when the Home button is pressed will be the coil that the controller subtracts material from as the machine is run.

A - 9

APPENDIX A

PLC CONTROLLER

Example:

The controller is set to run a black coil designated as Coil #2 and the user changes to a white coil designated by Coil #1. From the

Home screen, press the Coils button which will bring up the Coil

#2 information. Press the Coil #1 button and then the Home button.

If the remaining length reads negative then the machine has tracked more material than the purchased length.

Example:

controller will read a remaining length of -15’.

There is an indicator on the top right of the Home screen that indicates which coil is being tracked.

If a purchased length of 100’ is input into the controller then 115’ of material is ran through the machine before the coil is gone, the

Figure 63: Coil Indicator

Colors

Press the Change Color button to select the color of the coil. Press the Cancel button to avoid changing the color of the coil.

A - 10

APPENDIX A

PLC CONTROLLER

Figure 64: Coils Color Screen

Coil Length Calculator

The controller has a built in calculator to estimate the length of a coil based on the dimensions of the coil. From the Coils screen, press Length Calculator button.

Figure 65: Length Calculator Screen

Press the Select Material button to select the thickness and type of material.

A - 11

APPENDIX A

PLC CONTROLLER

Figure 66: Material and Thickness Screen

Then enter in the Inside Diameter of the Coil, Width of the coil and thickness of the coil.

The thickness of the coil is the difference between the Inside Diameter (ID) and the

Outside Diameter (OD). When all the fields are populated, the calculator estimates the length of the coil. Press the Done button to return to the Coils screen.

Figure 67: Coil Dimensions

A - 12

APPENDIX B

ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATICS

Sheet

Drawing Number Number Description

PLC-380-000

PLC-380-000

1

2

Electrical Assembly – Parts List

Electrical Assembly – Wiring Details

PLC-381-000

PLC-381-000

PLC-381-000

1

2

3

Control Box Assembly – Parts List

Control Box Assembly – Outside & Inside Views

Control Box Assembly – Wiring Schematic

PLC-381-000

PLC-381-000

4

5

Control Box Assembly – Ladder Logic 1

Control Box Assembly – Ladder Logic 2

B - 1

125

GND

EMERGENCY

STOP

N.C.

N.O.

102

85

MAIN CONTROL BOX

109

SHEAR

DOWN

N.O.

SHEAR

UP

(+)

N.C.

124

116

124

113

96

REV FOR

N.O.

108

N.C.

107

N.C.

119

122

START

FEED

N.O.

N.O.

(+)

MOTOR

START

N.O.

84

123

JOG-RUN

N.O.

97

104

STOP

FEED

N.C.

112

121

117

BLU

(-)

20

BLK

B

UP

SHEAR

A

BRN

(-)

DOWN

22

WHT

BLK

12

ENTRY END/REMOTE CONTROL

REMOTE

JOG

N.O.

FOR

N.O.

REV

BRN

11

10

WHT

BLU

13

REMOTE

STOP

N.C.

14

GRY

BRN

(+)

WHT

32

TOS-LEFT

N.O.

N.C.

30

BLK

BLU

31

CONTROL RELAYS

HTM (OPTIONAL)

2

3

(-)

4

(+)

120

7

2

118 114

HYD ON

(-)

5

4

6

3

CR3

8

1

51

413

(+)

OUT

5

1

110 111

SHEAR

7

105

2

5

4

6

CR2

8

1

3 115

116

7

2

103 106

MOTOR

(-)

5

4

6

3

8

CR1

1

117

119

BLK

(+)

BRN

52

HYDRO ON

N.O.

N.O.

51

53

BLU

WHT

COMPONENTS

BLU

(-)

70

BLK

B

REV

MOTOR

A

BRN

(-)

FWD

72

WHT

BLK

61

BRN

63

PANEL LENGTH

N.C.

96 97

GND

BLK

40

BRN

43

TOS-RIGHT

N.O.

N.C.

41

BLU

WHT

42

BOS

N.O.

N.C.

(-)

BLU

NOTE: UNLESS OTHERWISE SPECIFIED.

1. R=.015

MATERIAL

REV

SEE BOM

ECR NO.

DATE

LENGTH FINISH

RELEASED BY

TOLERANCES

.XX =

`.01

.XXX =

`.005

FRACTION =

`

ANGLE =

`

1/2

~

1/32"

DRAWN BY

DATE

CHECK BY

DATE

NEW TECH MACHINERY

CORP.

PART NAME

ELECTRICAL ASSEMBLY

PART NUMBER

PLC-380-000

SHEET

2

OF

2

REVISION

0

16

4

MEXICO ONLY

1

4X DRILL HOLES TO 1/4"

4

B

3

EARTH GROUND POINT

18

1

2

3

4

5

6

7

13

19 17

5

B

SECTION B-B

LABEL "REV 4"

ON INSIDE OF BOX

LENGTH: 42" FROM STRAIN RELIEF

MATERIAL

REV

SEE BOM

ECR NO.

DATE

LENGTH FINISH

RELEASED BY

TOLERANCES

.XX =

`

.01

.XXX =

`

.005

FRACTION =

`

1/32"

ANGLE =

`

1/2

~

DRAWN BY

DATE

CHECK BY

DATE


CORP.

PART NAME

CONTROL BOX ASSEMBLY

PART NUMBER

PLC-381-000

SHEET

2

OF

6

REVISION

4

120

A2

A1

REV

REMOTE

P1

FWD

COMM

N.O.

N.O.

N.O.

STOP

N.C.

N.C.

SHEAR

UP - DOWN

P2

-NEG

+POS

-NEG

+POS

TOS LS

LEFT

P3

N.O.

N.C.

N.C.

N.O.

WHT

BRN

BLK

BLU

GRY

10

11

13

12

14

BRN

WHT

BLU

BLK

22

[-]

20

[-]

BRN

WHT

BLU

BLK

32

+12V

31

30

TOS LS

RIGHT

P4

N.C.

N.C.

N.O.

N.O.

HYDRAULIC

ON P.S.

P5

N.O.

N.O.

N.O.

N.O.

BRN

WHT

BLU

BLK

42

43

41

40

BRN

WHT

BLU

BLK

53

52

+12V

51

BOS P.S.

P6

N.C.

NOT USED

COM -12

N.O.

BRN

WHT

BLU

BLK

63

[-]

61

MOTOR

FWD - REV

P7

-NEG

+POS

-NEG

+POS

BRN

WHT

BLU

BLK

[-]

72

[-]

70

BOTTOM OF BOX

12

14

11

H

M

T

OUT

IN

129

119

22 12

24 14

21 11

MTR

106

103

413

+12V

22 12

24 14

21 11

HYD

114

118

126

116

22 12

24 14

21 11

SHR

111

110

[-]

+12v

127

5

6

7

HOLE SEAL

HOT MELT

OPTION

1

2

3

4

GND

+12V

GND

[-]

83

84

85

GND

96

97

QCPP

PANEL LENGTH

LIMIT SWITCH

130

A2 A2

A1 A1 51

A2 A2

A1 A1

[-]

115

A2 A2

A1 A1

105

[-]

+12v

128

12

114 103

40 118

70 10

106 121

14

403

31 42

13 410

130 129

GND

GND

22

61

110

20

112

52

53

108

115

126

72

11

32

30

127

83

107

16

17

18

19

20

11

12

13

08

09

10

14

15

24

25

26

21

22

23

03

04

05

06

07

GND

GND

01

02

[-]

GND

413

412

411

410

409

408 406

405

404

403

+12V

128

304

305

308

109

404

120

104

122

411

405

113

123

111

306

117

GND

GND

408

412

309

409

406

63

105

43

41

125

113

FWD/REV

96

JOG/RUN

123

N.C.

N.O.

N.C.

N.O.

107 108 119 97

SHEAR UP

116

SHEAR DOWN STOP FEED

104

N.C.

+12V

N.O.

109

N.C.

112

E-STOP

GND 125

MOTOR START

84

N.O.

N.O.

N.C.

85

GND

+12V

309

308 306

305

304

REF PIN NUMBERS

START FEED

122

N.O.

N.O.

117 121

MATERIAL

REV

SEE BOM

ECR NO.

REF PIN NUMBERS

CABLE LENGTH: 42"

FROM STRAIN RELIEF

DATE

LENGTH FINISH

RELEASED BY

TOLERANCES

.XX =

`

.01

.XXX =

`

.005

FRACTION =

`

1/32"

ANGLE =

`

1/2

~

DRAWN BY

DATE

CHECK BY

DATE


CORP.

PART NAME


PART NUMBER

PLC-381-000

SHEET

3

OF

6

REVISION

4

LEGEND

1 TERMINAL BLOCK

2 PIN NUMBER

FUSE

CONTACT (N.O.)

CONTACT (N.C.)

MUSHROONM HEAD

PUSH BUTTON (N.O.)

MUSHROONM HEAD

PUSH BUTTON (N.C.)

PUSH BUTTON (N.O.)

PUSH BUTTON (N.C.)

LIMIT SWITCH (N.O.)

LIMIT SWITCH (N.C.)

PRESSURE SWITCH (N.O.)

PRESSURE SWITCH (N.C.)

CR1 CONTROL RELAY COIL

SO1 SOLENOID RELAY COIL

SELECTOR SWITCH

SPRING RETURN

SELECTOR SWITCH

MOMENTARY SWITCH

ROTARY ENCODER

LINE 1000

FROM QCPP

+12V

83

RED

11

128

YEL

F1

5A

127

YEL

10

125

YEL

E-STOP

N.C.

+12V

ORG

TO LINE 1006

1001

1002

1003

1004

1005

1006

1007

1008

1009

1010

1011

1012

1013

1014

1015

1016

1017

1018

1019

QCPP

GROUND

PANEL

LENGTH

GROUND

14

GRD

GRN

GRD

GRN

GND

VIO

GRD

GRD

GRD

GRN/YEL

GRD

GRN/YEL

N.O.

LOCATE GRD TOP

LEFT OF BOX

85

ORG

QCPP

GAS KILL

FROM QCPP

[-]

[-]

BLK

[-]

+12V FROM LINE 1000

+12V

+12V

BRN

T.O.S.

LEFT

N.O.

30

BLK

09

41

BLU

T.O.S.

RIGHT

N.O.

18

19

103

YEL

104

YEL

11

MTR

14

N.O.

STOP

FEED

N.C.

122

YEL

112

YEL

40

BLK

20

411

BRN/WHT

118

YEL

11 PLC IN (TOS)

11

HYD

14

N.O.

114

YEL

12

BLK

REMOTE BOX

REMOTE

FOR REV

FOR

N.O.

REV

N.O.

11

BRN

10

WHT

120

YEL

A1

HMT

A2

[-]

YEL

START

FEED

N.O.

121

YEL

106

YEL

22

123

YEL

N.O.

JOG RUN

N.O.

97

WHT

PANEL

LENGTH

N.C.

113

YEL

117

YEL

96

BLK

FOR REV

N.O.

108

YEL

107

YEL

PLC OUT (REV)

305

13

GRN/YEL

PLC OUT (FWD)

5

12

304

WHT

N.C.

26

4

405

GRN/YEL

21

130

YEL

404

WHT

16

17

A1

MTR

A2

70

BLK

MOTOR

REV

SO3

MOTOR

FOR

72

WHT

SO4

[-]

YEL

[-]

YEL

[-]

YEL

N.C.

119

YEL

21

MTR

24

N.O.

129

YEL

JUMPER INSIDE LEFT T.O.S.

TO LINE 1020

05

+12V FROM PLC BOX

406

ORG

6

10

306

ORG

REMOTE BOX

REMOTE

STOP

25

13

BLU

N.C.

410

RED

14

GRY

23

403

BLU

3 PLC IN (REMOTE STOP)

TO LINE 1020

MATERIAL

REV

SEE BOM

ECR NO.

DATE

LENGTH FINISH

RELEASED BY

TOLERANCES

.XX =

`

.01

.XXX =

`

.005

FRACTION =

`

1/32"

ANGLE =

`

1/2

~

DRAWN BY

DATE

CHECK BY

DATE


CORP.

PART NAME


PART NUMBER

PLC-381-000

SHEET

4

OF

6

REVISION

4

LEGEND

1 TERMINAL BLOCK

2 PIN NUMBER

FUSE

CONTACT (N.O.)

CONTACT (N.C.)

MUSHROONM HEAD

PUSH BUTTON (N.O.)

MUSHROONM HEAD

PUSH BUTTON (N.C.)

PUSH BUTTON (N.O.)

PUSH BUTTON (N.C.)

LIMIT SWITCH (N.O.)

LIMIT SWITCH (N.C.)

PRESSURE SWITCH (N.O.)

PRESSURE SWITCH (N.C.)

CR1 CONTROL RELAY COIL

SO1 SOLENOID RELAY COIL

SELECTOR SWITCH

SPRING RETURN

SELECTOR SWITCH

MOMENTARY SWITCH

ROTARY ENCODER

1035

1036

1037

1038

1039

LINE 1020

1021

1022

1023

1024

1025

1026

1027

1028

1029

1030

1031

1032

FROM LINE 1019

+12V

JUMPER INSIDE LEFT T.O.S.

FROM LINE 1019

-12V

+12V

BLK

+12V

YEL

+12V

WHT

+12V

YEL

+12V

YEL

08

32

WHT

43

BRN

SHEAR

UP

N.C.

116

YEL

T.O.S.

LEFT

N.C.

T.O.S.

RIGHT

N.C.

21

SHR

N.O.

24

124

YEL

126

YEL

31

BLU

42

WHT

14

15

24

111

YEL

12

SHEAR

DOWN

109

YEL

N.O.

308

GRY

SHR

11

N.C.

110

YEL

03

309

PNK

9

409

PNK

8

408

GRY

01

22

WHT

PLC OUT (SHEAR DOWN)

SHEAR

DOWN

SO1

115

YEL

A1

SHR

A2

105

YEL

07

53

BRN

HYD

ON

N.O.

04

52

WHT

20

BLK

SHEAR

UP

SO2

PLC OUT (SHEAR UP)

PLC IN (BOS)

51

BLU

06

63

BRN

12

412

BLK

02

A1

HYD

A2

61

BLK

B.O.S.

N.C.

N.O.

[-]

BLU

[-]

BRN

[-]

BLU

[-]

YEL

21

HYD

24

N.O.

413

BLU/WHT

QCPP

LATCH

MOTOR

START

13

84

BLU

N.O.

QCPP

START

PLC IN (HYDRO ON)

N.O.

QCPP

[-]

[-]

BLK

1033

1034

MATERIAL

REV

SEE BOM

ECR NO.

DATE

LENGTH FINISH

RELEASED BY

TOLERANCES

.XX =

`

.01

.XXX =

`

.005

FRACTION =

`

1/32"

ANGLE =

`

1/2

~

DRAWN BY

DATE

CHECK BY

DATE


CORP.

PART NAME


PART NUMBER

PLC-381-000

SHEET

5

OF

6

REVISION

4

CONTROL RELAYS

12 14

A2

HMT

A1

11

120

OUT IN

106 103

22

12

24

14

21

A2

MTR

A1

11

130

129 119

114 118

22

12

24

14

21

A2

HYD

A1

11

51

413 +12v

111

22

12

110

24

14

21

A2

SHR

A1

11

105

115

126 116

BLU

[-]

20

BLK

B

UP

SHEAR

A

BRN

[-]

DOWN

22

WHT

COMPONENTS

BLU

[-]

70

BLK

B

REV

MOTOR

A

BRN

[-]

FWD

72

WHT

BRN

+12v

WHT

32

TOS-LEFT

N.O.

N.C.

30

BLK

BLU

31

PANEL LENGTH

N.C.

96 97

GND

BLK

40

BRN

43

TOS-RIGHT

N.O.

N.C.

41

BLU

WHT

42

ENTRY END/REMOTE CONTROL

BLK

12

REMOTE

JOG

N.O.

FOR

N.O.

REV

11

BRN

10

WHT

BLU

13

REMOTE

STOP

N.C.

14

GRY

BLK

+12v

WHT

52

HYDRO ON

N.O.

N.O.

51

BLU

BRN

53

BLK

61

BRN

63

BOS

N.O.

N.C.

[-]

BLU

12

114 103

40 118

70 10

106

121

14 403

31 42

13 410

130 129

GND

GND

30

127

83

107

108

115

126

72

11

22

61

110

20

112

52

53

32

GND

GND

41

125

128

304

305

308

109

404

120

123

111

306

117

104

122

411

405

113

408

412

309

409

406

63

105

43

15

16

17

18

11

12

13

14

24

25

26

19

20

21

22

23

GND

GND

01

06

07

08

09

10

02

03

04

05

MATERIAL

REV

SEE BOM

ECR NO.

DATE

LENGTH FINISH

RELEASED BY

TOLERANCES

.XX =

`

.01

.XXX =

`

.005

FRACTION =

`

1/32"

ANGLE =

`

1/2

~

DRAWN BY

DATE

CHECK BY

DATE


CORP.

PART NAME


PART NUMBER

PLC-381-000

SHEET

6

OF

6

REVISION

4

SSH Roof Panel Machine Manual

SPECIFICATIONS

PRECAUTIONS

MACHINE ORIENTATION

GENERAL MAINTENANCE

Recommended Lubricants and Fluids

ELECTRICAL CONTROLS AND OPERATION

POWER CORD REQUIREMENTS

MANUAL CONTROL PANEL OPERATION:

ENTRY END CONTROL STATION

MAIN CONTROL CABLE

REMOTE LIMIT SWITCH

FUSES

ELECTRIC MOTOR MACHINES

REEL STANDS, REELS AND EXPANDABLE ARBORS

EXPANDABLE ARBOR

THREADED NUT

END COLLAR

LOADING EXPANDABLE ARBORS WITH COIL

LOADING REELED COIL

HYDRAULIC SYSTEMS

Maintenance

Hydraulic Fluid Troubleshooting

Changing Hydraulic Fluid and Filter

DRIVE SYSTEM

SHEAR ASSEMBLY

OPERATION

SHEAR ADJUSTMENTS

CHANGING AND ADJUSTING ENTRY AND EXIT SHEAR DIES

TOP SHEAR BLADE ADJUSTMENT

MAINTENANCE

BEAD AND STRIATION ROLLER ASSEMBLY

CLIP RELIEF ROLLER ASSEMBLY

ENTRY DRUM ASSEMBLY

WIDTH AND PROFILE CHANGE PROCEDURE

Tooling Changeover

Entry Guide Adjustment

Tooling Rail to Entry Guide Alignment

Shear Changeover

Loading Machine with Material

Bead Rollers (if equipped)

Shear Alignment

RUN OUT TABLES AND REMOTE LIMIT SWITCH

QUICK CHANGE POWER PAC (QCPP)

TROUBLESHOOTING

ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS

PLC CONTROLLER

Home

Manual Operation

Automatic Operation

Job Entry

Programming Jobs

Clear Jobs

Auto Run

Automatic Operation

On the Fly Calibration

Calibration

Setup:

Status/Diagnostics:

Security:

Coil Tracking:

Colors

Coil Length Calculator

ELECTRICAL SCHEMATICS

CONTROL RELAYS

COMPONENTS

ENTRY END/REMOTE CONTROL

Related manuals

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SSQ MultiPro

Ransomes

62350

Toro

Reelmaster 5010-H Traction Unit

Toro

5210/5410/5510/5610

Toro

5010-H

Toro

Reelmaster 5410 Traction Unit