TABLE OF CONTENTS CHAPTER 1……..SPECIFICATIONS ..................3 CHAPTER 2…..PRECAUTIONS ....................4 CHAPTER 3………. MACHINE ORIENTATION ................5 CHAPTER 4………. GENERAL MAINTENANCE ................. 7 Recommended Lubricants and Fluids............8 CHAPTER 5………. ELECTRICAL CONTROLS AND OPERATION .......... 9 CHAPTER 6………. REEL STANDS, REELS AND EXPANDABLE ARBORS ......
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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 ..................
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LIST OF FIGURES 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 ......................
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CHAPTER 1 SSH SPECIFICATIONS SPECIFICATIONS SSH Dimensions: Length-12’ 10” (3.9m) Width -3’ 10” (1.2m) Height-4’ 3” (1.3m) w/Over Head Rack 2’ 0” (.6m) w/o Over Head Rack Weight-2500 lbs. (1140kg) SSH on Trailer: Length-17’ 6” (5.3m) Width-7’ (2.1m) Height-6’ 3” (1.9m) with reel Weight-4500 lbs.
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CHAPTER 2 PRECAUTIONS PRECAUTIONS Make sure the operator of the machine has read and understands this manual in its entirety before attempting to operate this equipment. ALWAYS keep covers, guards and lids mounted to machine during operation OBSERVE and OBEY all safety and warning signs affixed to the machine. ALWAYS adhere to and follow all local and national safety codes concerning the loading and un-loading of reeled coils.
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CHAPTER 4 GENERAL MAINTENANCE 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.
CHAPTER 4 GENERAL MAINTENANCE Recommended Lubricants and Fluids Spray Lube for: Shear Blades, Dies, Entry Guide, Bead Roller Carriage Shafts and chains Super Lube - Multi-Purpose Synthetic Dri Film Aerosol Lubricant with Syncolon (PTFE) Catalog No. 11016 11 oz. Aerosol Can Available from: MSC Supply at 1-800-645-7270 Clear Grease for:...
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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION ELECTRICAL CONTROLS AND OPERATION POWER CORD REQUIREMENTS For machines equipped with a QCPP-E it is very important to follow the power cord requirement prescribed by the motor and electrical control manufacturers to maintain their respective warranties. Make sure the cord being used is marked properly. Do not assume that because an extension cord looks heavy enough that it is the right gauge.
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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION 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.
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CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION 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.
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION Figure 6: Main Control Box Fuse Figure 7: QCPP E 1-6 Fuse Location...
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CHAPTER 6 REEL STANDS, REELS AND EXPANDABLE ARBORS REEL STANDS, REELS AND EXPANDABLE ARBORS EXPANDABLE ARBOR (Figure 8 on page 17) 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.
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CHAPTER 6 REEL STANDS, REELS AND EXPANDABLE ARBORS CAUTION: Always use properly rated lifting devices to load and unload coils. Maximum Capacity / Reel: 3,000 lbs. Total Capacity for Reel Stand: 6,000 lbs. 1. The reel shafts must rest in the arbor cradles on the reel rack. Keep the arbor cradles lubricated with clear grease to minimize wear.
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CHAPTER 6 REEL STANDS, REELS AND EXPANDABLE ARBORS LOADING REELED COIL Caution: Always use a forklift or other approved lifting device to load or unload Fixed Reels or Expandable Arbors loaded with coil. The Lifting Holes in the Fixed Reel sides are provided to make loading safer and easier. DO NOT use lifting straps through the lifting holes as the sharp edges may cut the straps.
CHAPTER 7 HYDRAULIC SYSTEM AND SCHEMATIC HYDRAULIC SYSTEMS Maintenance (Figure 11 on page 23) 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.
CHAPTER 7 HYDRAULIC SYSTEM AND SCHEMATIC Figure 12: Hydraulic System – Details Figure 13: Hydraulic Fluid Level...
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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.
CHAPTER 8 DRIVE SYSTEM Figure 16: Upper and Lower Chains...
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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.
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.
CHAPTER 9 SHEAR ASSEMBLY Figure 18: Shear Die Detail Views...
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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.
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CHAPTER 10 BEAD AND STRIATION ROLLER ASSEMBLY BEAD AND STRIATION ROLLER ASSEMBLY (Figure 19 on page 34) 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.
CHAPTER 11 CLIP RELIEF ROLLER ASSEMBLY CLIP RELIEF ROLLER ASSEMBLY (Figure 20 on page 35) 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.
CHAPTER 12 ENTRY DRUM ASSEMBLY ENTRY DRUM ASSEMBLY (Figure 21 on page 36) 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.
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.
CHAPTER 13 PROFILE CHANGEOVER PROCEDURE Entry Guide Adjustment (Figure 24 on page 41) 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.
CHAPTER 13 PROFILE CHANGEOVER PROCEDURE Tooling Rail to Entry Guide Alignment (Figure 23 and Figure 24 on pages 39 and 41) 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.
CHAPTER 13 PROFILE CHANGEOVER PROCEDURE Figure 25: Feeding Material into Entry Guides 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”...
CHAPTER 13 PROFILE CHANGEOVER PROCEDURE Bead Rollers (if equipped) (Figure 19 on page 34) 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. Determine the spacing needed.
CHAPTER 13 PROFILE CHANGEOVER PROCEDURE 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. Adjust the exit male shear die assembly so that it is offset to the outside of the entry die by approximately 1/64”...
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CHAPTER 14 RUN OUT TABLES AND REMOTE LIMIT SWITCH RUN OUT TABLES AND REMOTE LIMIT SWITCH (Figure 28 and Figure 29 on pages 47 and 48) 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.
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CHAPTER 14 RUN OUT TABLES AND REMOTE LIMIT SWITCH Figure 28: Run Out Table...
CHAPTER 14 RUN OUT TABLES AND REMOTE LIMIT SWITCH Figure 29: Run Out Table Setup...
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CHAPTER 15 QUICK CHANGE POWER PAC QUICK CHANGE POWER PAC (QCPP) (Figure 30 and Figure 31 on pages 49 and 50) 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 their machine at the jobsite with a gas engine and use it in a factory or indoor setting with an electric motor as well.
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CHAPTER 15 QUICK CHANGE POWER PAC Figure 31: Quick Change Power Pac Types...
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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.
CHAPTER 16 TROUBLESHOOTING Figure 32: Top of Stroke Limit Switch Figure 33: Limit Switch Adjustment Screws...
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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.
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.
APPENDIX A PLC CONTROLLER Pre-Run Sequence: 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.
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.
APPENDIX A PLC CONTROLLER Automatic Operation 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.
APPENDIX A PLC CONTROLLER Figure 56: Calibration Screen 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.
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” 124 1/16”...
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.
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.
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.
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.
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).
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APPENDIX B ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS Sheet Drawing Number Number Description PLC-380-000 Electrical Assembly – Parts List PLC-380-000 Electrical Assembly – Wiring Details PLC-381-000 Control Box Assembly – Parts List PLC-381-000 Control Box Assembly – Outside & Inside Views PLC-381-000 Control Box Assembly –...
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Parts List ITEM PART NUMBER TITLE ELC-300-138 GROMMET, 3/4" ID, 1-1/2" OD FAS-HC5-118 HEX HEAD CAP SCREW, 1/4-20 x 1" LG. FAS-HC5-278 HEX HEAD CAP SCREW, 1/4-20 x 2" LG. FAS-NUY-188 NYLOC HEX NUT, #1/4-20 FAS-SRM-207 SCREW, PAN HEAD, 8 x 1/2", PHIL, SELF-TAPPING INSTALL GROMMET FAS-WSF-260 WASHER, FLAT, 1/4"...
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MAIN CONTROL BOX REV FOR START SHEAR FEED N.O. EMERGENCY DOWN STOP N.O. N.O. COMPONENTS N.C. N.C. SHEAR N.O. PANEL LENGTH N.O. N.C. N.C. STOP N.C. MOTOR JOG-RUN FEED START N.C. N.O. N.O. SHEAR MOTOR DOWN ENTRY END/REMOTE CONTROL REMOTE N.O.
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PARTS LIST ITEM PART NUMBER TITLE ELC-100-006 TERMINAL BLOCK, 10A ELC-100-007 DIN RAIL STOP (NOT SHOWN) ELC-100-008 TERMINAL BLOCK JUMPER (NOT SHOWN) ELC-100-017 FEMALE CLOSURE CAP ELC-100-018 MALE CLOSURE CAP ELC-100-021 ENCLOSURE ELC-100-025 RECEPTACLE, 4 PIN MALE x.5M ELC-100-026 RECEPTACLE, 5 PIN MALE x.5M ELC-300-101 FUSEHOLDER BUS HKP ELC-300-103...
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SECTION B-B LENGTH: 42" FROM STRAIN RELIEF LENGTH: 24" FROM STRAIN RELIEF NEW TECH MACHINERY MATERIAL LENGTH FINISH CORP. SEE BOM SECTION A-A TOLERANCES DRAWN BY PART NAME ECR NO. DATE RELEASED BY .XX = CONTROL BOX ASSEMBLY DATE TO ATTACH TERMINAL BLOCK .XXX = .005 MOUNTING PLATE TO ENCLOSURE...
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N.O. GROUND TO BOX REMOTE N.O. N.O. N.O. COMM START FEED N.O. N.C. STOP N.O. N.C. N.C. -NEG SHEAR N.C. STOP FEED +POS UP - DOWN -NEG +POS N.O. N.O. JOG/RUN N.O. TOS LS N.O. N.C. 403 123 LEFT N.O. N.C.
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E-STOP FROM QCPP LINE 1000 +12V TO LINE 1006 N.C. 1001 LEGEND QCPP 1002 GROUND WIRE NUMBER PIN NUMBER PANEL QCPP-GAS 1003 LENGTH KILL SWITCH FUSE GROUND N.O. CONTACT (N.O.) 1004 CONTACT (N.C.) LOCATE GRD TOP FROM QCPP LEFT OF BOX MUSHROONM HEAD 1005 -12V...
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FROM LINE 1019 FROM LINE 1019 +12V -12V LINE 1020 SHEAR T.O.S. LEFT 1021 N.C. N.C. T.O.S. PLC OUT (SHEAR UP) LEGEND RIGHT 1022 WIRE NUMBER N.C. PIN NUMBER 1023 FUSE SHEAR SHEAR DOWN CONTACT (N.O.) 1024 CONTACT (N.C.) N.C. N.O.
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i have a ssh with snaplock and its cracking the metal panels at the L-4 L-4.5 rollers, i dont see the L4.5 on your manual on the website