VS-150 MACHINE OWNERS MANUAL

VS-150 MACHINE
OWNERS MANUAL
ROLL FORMER CORP.
140 INDEPENCENCE LANE ● CHALFONT, PA 18914
215-997-2511 ● FAX: 215-997-5544
www.rollformercorp.com
TOP VIEW
ENTRANCE
Clutch
Handle
Hydraulic
Pump
Crank Handle
(width Adjustment)
Hydraulic
Motor
E-Stop
RIGHT SIDE
EXIT
LEFT SIDE
OPERATING INSTRUCTIONS
ROLL FORMER PANFORMER MODEL VS-150
ELECTRIC - HYDRAULIC DRIVE
This machine operates on 110 volt/60HZ. Be sure that the proper power supply and cable are used to deliver maximum power to the unit. Use only a three wire extension cord which has a three prong grounding
plug and a three prong receptacle. Recommended wire sizes for extension cords; 25’ - 16 gauge, 50’ - 14
gauge and 100’ - 12 gauge.
If motor stops under load, check voltage level under load at the motor terminals for 110V min. KEEP THE
GUARDS ON WHENEVER THE MACHINE IS IN OPERATION TO AVOID INJURY!
The unit is hydraulically powered and the electric motor turns on but the forming rolls will not turn until forward/reverse is activated. It may be necessary to adjust the pressure at the hydraulic pump. Please refer to
the hydraulic pump manual for this operation.
ENTRANCE GUIDES
The entrance guides determine the amount of material that is fed into the forming rolls and keeps the material straight when entering the machine. The location of these guides dictate the physical dimensions of the
panel profile.
A)
The VS-150, which has the shear attachment, will have two sets of guide plate assemblies, each
mounted to a guide plate slat. One set located in front of the shear (C & D) and the other behind it
(A & B). The guides should always be parallel to the first stage and parallel to one another.
Shear
B
A
C
Pinch/Feed
Rolls
D
THE MOST IMPORTANT FACTOR IN THE OPERATION OF THE MACHINE IS
THAT THE MATERIAL ENTER THE MACHINE STRAIGHT. When using a coil, the
decoiler should be located with the left side of the material being exactly in line with
the left side guides. If possible, try to have at least 4’ of distance from Decoiler to the
front entrance guides of the machine.
B) All of the entrance guides are movable by simply loosening the cam follower (Allen
Head) and sliding to desired setting. These guides are factory set and scribed with lines
which indicate proper dimensions for a standard 1” and 1 1/2” standing seam.
Scribe
Lines
Camfollower—
Loosen to adjust
C)
To form “U-panels” in either 1” OR 1½” heights, adjust front and middle, left
side guide plates to the right of the standing seam scribe line approximately 3/4” to
13/16” to “cheat the machine of material. On the right side of the panel move the
moveable rail approximately 5/16” - 3/8” out away from the movable rail scribe line
to “cheat” the machine of material on the male leg.
D)
To set the width of your panel, loosen the “D” entrance guide and slide it out of the
way so that the material will clear and pass through to the feed rolls.
E)
The feed rolls are located in front of the shear. These rolls help pull the material into
the machine, hold and feed after the shear has cut. The feed rolls have a clutch
which allows them to spin freely or be driven. When the clutch is pulled out, the
feed rolls will idle or can be rotated by hand. When the clutch is engaged, the feed
rolls are driven when the machine is operated .
F)
Using the crank on the right side of the machine, adjust the movable rail until the
material clears guide ”B” and rests against guide “A”. When the material is resting
against the guides “A and C”, slide guide “D” over until it touches the r/s edge of the
material and tighten camfollowers slide guide B over until it touches the r/s edge of
material and tighten camfollower.
The material should now be in the machine with all four of the entrance guides touching the edges of the material. Move material in and out between entrance guides to
be sure of this. Material should glide smoothly between these four guide plate assemblies. Adjust r/s guides B&D if necessary.
Now crank the adjustable rail back in until the appropriate scribe line for either 1” or 1
1/2” matches the edge of the material.
SMALL ROLL BLOCK ADJUSTMENT
The VS-150 is designed to change quickly and easily with a minimum of adjustment.
This machine is equipped with roll mounting blocks that locating pins for easy and precise alignment. On both sides of the machine the powered forming rolls are nonpowered idling forming rolls. The powered rolls are sequentially numbered, starting in
the front of the machine (where the material enters) R1-R10 (right) and L1-L10, (left).
The non-powered stages are located between the powered stages and are numbered
R1.5, R2.5 etc.
Changing the panel leg height is very simple
as shown in the drawings. Simply remove
the locking bolt from the main block, and remove the block with the forming rolls from
the locating pins. When changing sizes it is
not necessary to remove the stationary
block from the rail.
Reinstall the block onto the locating pins either one hole up or down depending on the
height change required and replace the
locking bolt.
* After completion of the change-over remember that you will have to reset the entrance guides to give proper dimensions to
the legs.
Block set to form 1”
Block set to form 1½”
CAMBER ADJUSTMENT
A)
Run the machine until the panel clears the rear about 5 feet. With panel still
extending from rear of the machine, sight along bottom of panel and check to
see if the panel is straight. THIS IS KNOWN AS CAMBER AND MAY BE
THE SINGLE MOST IMPORTANT ADJUSTMENT ON THE MACHINE.
B)
Adjust Camber Rolls (long tubes that span width of machine): Due to
the differences in the material yield strength, this adjustment may be necessary. Start by determining how much you wish to move the rolls, If the panel
curves down, adjust the Camber Rolls up to compensate. If the panel
curves up, adjust the Camber Rolls down.
1.
2.
3.
Loosen or tighten the hex head bolt located on top of each Camber
Block, the desired amount of the adjustment.
Using an Allen wrench, loosen the locking screw to the Camber
Block on the appropriate side of the machine located through the
side rear guard. Note that each side can be adjusted independently.
Tighten the locking screw and jam nuts on Camber Blocks after adjust
ment is made.
Now check to make sure that the bottom of your panel is straight on
both sides.
CAMBER TUBES T/B
Loosen Corner post
mounting bolt to allow
camber stage to move
up or down
Loosen Fine Adjustment nut
and bolts to allow camber
stage to move up or down
Camber Block R/L
CAMBER UP
CAMBER DOWN
C) It is very important that the panel is supported as it exits the machine so that it is
not bowed by its own weight. Any type of smooth table that is level with the machine will work well.
D)
After the first panel is produced, check the panel dimensions to be sure that the panels will
interlock and have the proper dimensions.
E)
To ensure that you obtain the best possible results, by either making two panels and interlocking or by slitting the panel down the middle and then interlocking to check for proper
nesting. If edge “B” is too narrow it will possibly cause the seamer to not give the best results.
Fixed Dimension
5/16” minimum
3/8” Maximum
Minimum 5/16”
Maximum 3/8”
F) If the length of any of the panel edges are not satisfactory, lengthening or reducing the legs can
be easily accomplished by adjusting the entrance guides. The entrance guides determine how
much material is fed into the forming rolls. For example: if the panel leg ”A” is too short, then
you would move the entrance guides “A” and “C” out as much as you would like that dimension
to be increased. IT IS VERY IMPORTANT THAT THE ENTRANCE GUIDES “A” AND “C” ARE
ALWAYS MOVED IN EXACTLY THE SAME INCREMENTS OR ELSE THE MATERIAL WILL
NOT FEED STRAIGHT. If you are moving the left guides out, you will have to adjust the movable rail in, to compensate for the amount that you moved “A” and “C” out. This may sound
complicated, however, once a few minutes are spent operating the machine you will how simple it really is. The same adjustment can be made to the other side of the panel if necessary.
FINE TUNING
A)
Set Top Leg Support Assembly to desired height (1” or 1.5”) by screwing assembly into
proper hole in right side rail at stage 10. Then adjust Eccentric by turning hex portion of
assembly that causes the roll to rest on top of male leg of the panel. (See photo).
The next two steps allow you to manipulate the upright legs of the panel to achieve a 90° angle:
B)
Set the Bumper Plate and Roll Assembly to the right side rail at Stage 10, and then use the
slots in the plate to position the roll so it just touches the outside edge of the male leg. (See
photo).
C)
Set Large Top 45° Angle Roll Assembly by loosening the hex head bolts in the ends of the
TR10 angle blocks, then positioning the roll by adjusting the spring screw so that t h e
r o ll
rests in the inside corner of the male leg. Then tighten hex head bolts. (see photo).
VS-150 FINE TUNING
Top Leg Support
Assembly (with
Hex Eccentric
Bumper Plate and
Roll Assembly
Large Top 45° Angle
Roll Assembly
SHEAR
SCISSOR SHEAR
The scissor shear should be kept lubricated to prevent rust. If in the event that
the scissor shear does not make a clean cut or does not cut across the entire
sheet, simply snug up the pivot locking bolt. The scissor shear should give
thousands of clean cuts and if necessary can be sharpened locally for short
down time.
IV-1
SHEAR
A)
The shear should be kept lubricated to prevent rust. If in the event that the shear
does not make a clean cut or does not cut across the entire sheet, simply tighten
the pivot locking bolt. The shear should give thousands of clean cuts and if necessary can be sharpened locally for short down time.
GENERAL SPECIFICATIONS AND MAINTENANCE
Material capacities - 24 gauge steel (painted or not) A-B-C grade
.024 - .032 aluminum (20,000 KSI)
12 - 20 oz. copper (half hard)
Material with flat stock 12 - 28 1/2.
(A seam height of 1” uses 3” of width and a seam of 1.5” uses 4” of material).
Hexagonal shafts must be kept clean. DO NOT use OIL OR GREASE on these shafts.
This will attract dust and grit which will stick and cause wear. Simply wipe the shafts
clean and apply a SILICONE SPRAY LUBRICANT.
Galvanized steel and some other coated sheet may leave a deposit on the stainless steel
forming rolls. If this is a problem, it may be prevented by applying a light coating of
“GALV-OFF” (a product of the Lock former Corp.) on the STEEL PORTION OF THE
FORMING ROLLS ONLY. should a deposit build up it can be removed using a fine
abrasive cloth, such as “SCOTCHBRITE” made by the 3M Company.
To clean the RUBBER ROLLS use a DEGREASING SOLVENT and a clean cloth. Do
not attempt to clean rolls while the machine is plugged in. The material chosen to roll
form is very important to the quality of the finished panel.
It is very important that your material has a constant width, if it is not even, you will get
uneven edges on your panels.
It is normal to get a small amount of edge flair at the beginning and end of the panel.
This is normal and does not affect the seaming or appearance of the finished job.
The installation of your panels is the most important aspect of your job. The underlayment and overall flatness of the roof deck will be the greatest factor in determining the
overall flatness of the metal roof.
If your edges gradually gain or lose material over the length of the sheet, your entrance
guides may not be set parallel to the forming rolls. What you lose on one edge, you will
gain on the other. To compensate, move the left rear guide “C” toward the side that
loses the material, about .050. Adjust the guide back over the edge of the material. Run
another panel and check the legs again. More or less adjustment may be needed.
16
16
#4
20
16
MOTOR
16
16
16
16
16
16
16
16
16
16
16
BOTTOM STAGES
#5
#6
16
16
#7
16
16
#8
16
16
#9
16
16
#10
16
16
TOP STAGES
#2
16 SPUR
16
16
15
16
16
STG#1
16
16
16 SPUR
#3
16
16
VS-150 SPUR GEAR AND SPROCKET LAYOUT
30 MARCH 00
16
CLUTCH
When transporting the machine, transport with a piece of material in the machine and
put the shear in the down position.
Keep machine out of rain and dampness if possible.
Lubricate any area of the machine that shows any signs of rust.
VERY IMPORTANT
Disconnect all power before removing any covers on the
machine.
Disconnect all power before servicing and adjusting the
machinery.
Do not operate the machine at any time with the covers
removed.
Troubleshooting panel run out (tapering)
on front shear style machine
Items to check before disturbing guide plates:
1)
Check clutch chain on left side of machine for tauntness.
See photo #1 blocks can be adjusted on either side of machine
Photo #1
2)
Check rails to see if parallel. Using a tape measure, measure between rails at entrance of
machine and exit of machine. If rails are not parallel adjust by removing acme nut cover
plate and turning acme nut in or out to desired position.
See photo #2 and 3 Ideally rails should be parallel end to end with at the most 1/32” wider
out exit of machine.
Photo #2
Photo #3
3)
If top two items are ok proceed with step #4.
4)
To elimate run out the machine will have to be tested with precut 4 foot long
sheets.
5)
Mark guide plates and guide plate mounting slats with a pen.
See photo 4 and 5.
Photo #5
Photo #4
6)
Loosen front guides (before shear) and slide toward outsides of machine.
See photo 6.
Photo #6
7)
Adjust the top pinch rolls up so metal can slide freely between rolls. This is
done by loosening the four bolts on either side of the machine.
See photo #7
Photo #7
8)
Slide metal into machine through middle guide plates.
See photo #8 (make sure all four camfollowers are making contact)
Photo #8
9)
Run panel through machine and measure front and back of female down leg
for runout. Take measurement approximately 6” from either end.
10)
If panel grows on the female or L/S of panel adjust the L/S of the guide plate
mounting slat (¼ x 3 steel) toward the front or feed end of the machine.
See photo #9 – If panel becomes smaller adjust toward exit of machine. If no
run out is present proceed to Step 12
Photo #9
11)
Run test panels using the middle guide until the desired length of leg and
trueness is achieved.
12)
After achieving a good panel using the middle guide. Measure and adjust the
front guide plate slat (¼ x 3) so it is parallel to the middle guide.
See Photo #10
Photo #10
13)
Slide metal into machine through guide plates on the middle guide.
14)
Adjust the front guides l/s and r/s over to nestle against the sides of the
panel. (See photo #11). Slide panel back and fourth making sure material is
making contact with camfollowers. Material should be snug against sides but
should not hit hard against second set of guides. Some adjusting of front
guides maybe necessary for a smooth transition between guides.
Photo #11
15)
Run test panel through machine. L/S leg should not taper. If run out occurs
check front guide again.
16)
After achieving good panels through both guides, check and adjust pinch roll
block assemblies for parallel, measure between front of guide slat and pinch
roll block. See photo #12. Adjust by loosening bolts on either side of
machine.
Photo #12
17)
Adjust pinch rolls down by four bolts on top of either side of machine. See
photo #7. The distance between the blocks should be ¾”. Both sides have
to be adjusted evenly so material pulls into machine evenly.
18)
Run test panel through machine. Panel should not be tapered. If it is double
check adjustment of pinch rolls.
19)
If test panels are ok after Step #18 machine should be able to run off of coil.
Make sure decoiler is set 6 to 8 foot in front of machine and in line.
STANDARD EQUIPMENT WARRANTY
Roll Former Corporation warrants to the original purchaser that the equipment is free from defects in material and workmanship in normal use and service. Normal use and service does
not extend to defects from mishandling, tampering or modifying the equipment.
The term of this warranty is for a period of ninety (90) days for the Seamer and three hundred and sixty five (365) days/one year (1) for all other Roll Forming Equipment from the
date of the receipt of the equipment to the original purchaser. Roll Former Corporation
shall repair or replace the defective parts at their place of business without charge to the original purchaser of the equipment.
The equipment subject to this warranty must first be returned to Roll Former Corporation with
freight charges prepaid, which after examination by Roll Former Corporation shall disclose to
its satisfaction to have been defective. Roll Former Corporation shall correct the defect and
ship the prepaid equipment to the location of the purchaser’s facility within the continental
United States.
The foregoing warranties are in lieu of all other warranties expressed or implied, and of all obligation or liabilities on the part of Roll Former Corporation for breach of warranty.
Roll Former Corporation’s sole liability for any breach of warranty shall be limited to the repair
or replacement of any defective parts in the accordance with the above.
Roll Former Corporation’s warranty does not extend to equipment that has been used under a
lease or rental agreement from the original purchaser.
CUSTOM EQUIPMENT - WARRANTY AND LIABILITY
Roll Former Corporation’s liability for custom equipment prior to acceptance, is the amount of
deposit from the customer. Roll Former warrants, after acceptance, all custom equipment for a
period of three hundred and sixty five (365) days/one year (1) from the date of the receipt of
the equipment to the original purchaser that the equipment is free from defects in material and
workmanship in normal use and service.
The equipment subject to this warranty must first be returned to Roll Former Corporation with
freight charges prepaid, which after examination by Roll Former Corporation shall disclose to
its satisfaction to have been defective. Roll Former Corporation shall correct the defect and
ship the prepaid equipment to the location of the purchaser’s facility within the continental
United States.
The foregoing warranties are in lieu of all other warranties expressed or implied, and of all obligation or liabilities on the part of Roll Former Corporation for breach of warranty.
Roll Former Corporation’s sole liability for any breach of warranty shall be limited to the repair
or replacement of any defective parts in the accordance with the above.
Warranty will not be available if any of the following occurs:
1. Mishandling - tampering or modifying equipment.
2. Leasing or renting equipment.