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MAZZELLA NTM BG7 Operation And Maintenance Manual

7" commercial box gutter machine
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  • Page 2: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1……..SPECIFICATIONS ..................1 CHAPTER 2…..PRECAUTIONS ....................2 CHAPTER 3………. GENERAL MAINTENANCE .................3 Recommended Lubricants and Fluids ............4 CHAPTER 4………. ELECTRICAL CONTROLS AND OPERATION ..........5 CHAPTER 5………. REEL STANDS, REELS AND EXPANDABLE ARBORS ......11 CHAPTER 6………. HYDRAULIC SYSTEMS ................16 Maintenance ...................16 Hydraulic Fluid Troubleshooting ............16 CHAPTER 7……….
  • Page 3 LIST OF FIGURES Figure 1: Controls ..........................8 Figure 2: Main Control Cable ......................9 Figure 3: Main Control Box Fuse ..................... 10 Figure 4: QCPP E 1-6 Fuse Location ....................10 Figure 5: Expandable Arbor Set-Up ....................12 Figure 6: Expandable Reel Assembly ....................14 Figure 7: Hydraulic System –...
  • Page 4 CHAPTER 1 BG7 SPECIFICATIONS SPECIFICATIONS BG7 Dimensions: Length-14’ 6” (4.4m) Width-4’ (1.7m) Height-4’ 3” (1.3m) w/Over Head Rack 2’ 8” (.8m) w/o Over Head Rack Weight-1800 lbs. (820kg) SSQ on Trailer: Length-21’ (7.7m) Width-7’ (2.1m) Height-6’ 3” (1.9m) with reel Weight-4560 lbs.
  • Page 5 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.
  • Page 6 CHAPTER 3 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 your machine with a tarp to protect it but provide good ventilation to prevent condensation and rust.

  • Page 7: Chapter 1

    CHAPTER 3 GENERAL MAINTENANCE Recommended Lubricants and Fluids Spray Lube for: Shear Blades, Dies, and Entry Guide Super Lube - Multi-Purpose Synthetic Dri Film Aerosol Lubricant with Syncolon (PTFE) Catalog No. 11016 11 oz. Aerosol Can Available from: MSC Supply at 1-800-645-7270 Clear Grease for: Arbor Cradles Synthetic Extreme Pressure, High Temperature Grease with Syncolon (PTFE)
  • Page 8 CHAPTER 4 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.
  • Page 9 CHAPTER 4 ELECTRICAL CONTROLS AND OPERATION Function #1 (Power On) Pull this button OUT prior to starting the machine. Function #2 (Emergency Stop-Power Off) Once the machine is running, pushing this button in will stop all functions and completely shut down the machine including the engine. If the shear is in the down cycle it will freeze it in position.

  • Page 10: Chapter 4

    CHAPTER 4 ELECTRICAL CONTROLS AND OPERATION FUSES (Figure 3) All machines, gas or electric powered, have a 10-amp time delay fuse inside the Electrical Control Panel Assembly. This fuse protects the electrical components. If the fuse is blown, you will lose all functions of the machine except Motor Start. To replace this fuse: Loosen all 4 cover screws and open the front panel of the Control Box.

  • Page 11: Chapter 5

    CHAPTER 4 ELECTRICAL CONTROLS AND OPERATION Figure 1: Controls...

  • Page 12: Chapter 6

    CHAPTER 4 ELECTRICAL CONTROLS AND OPERATION Figure 2: Main Control Cable...

  • Page 13: Figure 3: Main Control Box Fuse

    CHAPTER 4 ELECTRICAL CONTROLS AND OPERATION Figure 3: Main Control Box Fuse Figure 4: QCPP E 1-6 Fuse Location...
  • Page 14 CHAPTER 5 REEL STANDS, REELS, AND EXPANABLE ARBORS REEL STANDS, REELS AND EXPANDABLE ARBORS EXPANDABLE ARBOR (Figure 5) The Expandable Arbor adjusts to accommodate coils with 16” to 20” inside diameters by expanding into the ID of the coil. THREADED NUT The threaded nut should always be on the right side of the machine and the tail of the coil should always be routed over the top and pointing toward the exit or shear end of the machine.

  • Page 15: Figure 5: Expandable Arbor Set-Up

    CHAPTER 5 REEL STANDS, REELS, AND EXPANABLE ARBORS Figure 5: Expandable Arbor Set-Up...
  • Page 16 CHAPTER 5 REEL STANDS, REELS, AND EXPANABLE ARBORS CAUTION: Always use properly rated lifting devices to load and unload coils. Maximum Capacity / Reel: 3,000 lbs. Total Capacity for Reel Stand: 6,000 lbs. 1. The reel shafts must rest in the cradles on the reel rack. Keep the cradles lubricated with synthetic lube to minimize wear.

  • Page 17: Figure 6: Expandable Reel Assembly

    CHAPTER 5 REEL STANDS, REELS, AND EXPANABLE ARBORS Figure 6: Expandable Reel Assembly...
  • Page 18 CHAPTER 5 REEL STANDS, REELS, AND EXPANABLE ARBORS LOADING REELED COIL Caution: Always use a forklift or other approved lifting device to load or unload Fixed Reels or Expandable Arbors loaded with coil. The Lifting Holes in the Fixed Reel sides are provided to make loading safer and easier. DO NOT use lifting straps through the lifting holes as the sharp edges may cut the straps.

  • Page 19: Maintenance

    CHAPTER 6 HYDRAULIC SYSTEMS HYDRAULIC SYSTEMS Maintenance (Figure 7) The hydraulic system for your machine is a very durable and reliable system. It must be properly maintained to ensure trouble free operation and longevity. The factory has installed a 32 weight AW hydraulic fluid.

  • Page 20: Chapter 7

    CHAPTER 6 HYDRAULIC SYSTEMS Figure 7: Hydraulic System – Overview...

  • Page 21: Chapter 8

    CHAPTER 6 HYDRAULIC SYSTEMS Figure 8: Hydraulic System – Details Figure 9: Hydraulic Fluid Level...

  • Page 22: Chapter 9

    CHAPTER 7 DRIVE SYSTEM DRIVE SYSTEM The drive rollers are set at the factory and should not need adjustment. Over time, the chains will wear down causing them to get longer and the chain tensioning sprockets will need to be adjusted to keep the chain tight.

  • Page 23: Figure 11: Shear Height Adjustment

    CHAPTER 8 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.

  • Page 24: Chapter 10

    CHAPTER 8 SHEAR ASSEMBLY Adjusting the left-right position of the shear: 1. Shut off power to the machine 2. Remove the shear cover, then loosen the six “A” bolts but do not remove. 3. Use a large screwdriver to pry on the slots (Figure 12) until the shear is located correctly. 4.

  • Page 25: Chapter 11

    CHAPTER 8 SHEAR ASSEMBLY SHEAR 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.

  • Page 26: Chapter 12

    CHAPTER 9 ENTRY GUIDE & DRUM ASSEMBLY ENTRY GUIDE AND DRUM ASSEMBLY ENTRY GUIDE ADJUSTMENT Figure 13: Entry Guide Adjustment ENTRY DRUM ADJUSTMENT Figure 14: Entry Drum Adjustment...

  • Page 27: Chapter 13

    CHAPTER 10 RUN OUT TABLES RUN OUT TABLES (Figure 15) The Run-Out Table attaches to the Exit End of the Shear assembly, and is used to support the gutter 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.

  • Page 28: Figure 16: Post Face Knife Roller Adjustment

    CHAPTER 11 POST-FACE KNIFE ROLLER ADJUSTMENT POST-FACE KNIFE ROLLER (Figure 16) When changing the coil from steel to aluminum, or vice-versa, the post-face knife roller needs to be adjusted in order to maintain a quality gutter. To do this, follow the procedure below and refer to Figure 22.

  • Page 29: Figure 17: Pressure Switch Adjustment

    CHAPTER 12 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.
  • Page 30 CHAPTER 12 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: Press and hold the Green Shear Down Button until the panel is cut off.

  • Page 31: Figure 18: Limit Switch Adjustment

    CHAPTER 12 TROUBLESHOOTING Figure 18: Limit Switch Adjustment 4. Manual Control Panel buttons do not work. SOLUTION #1: Check fuse inside of Manual Control Box. Replace if blown with a 10-amp time delay fuse (Figure 3 on page 10). SOLUTION #2: If you have a gasoline engine, check the condition of the battery. The control system requires 12 volts to operate properly.

  • Page 32: Engaging Or Disengaging The Hook

    CHAPTER 13 HOOK ASSEMBLY (OPTIONAL) HOOK ASSEMBLY (OPTIONAL) (Figure 19) The Hook Assembly is a self-contained assembly which can be added to a gutter machine. The New Tech machine is capable of running a straight back (with a bead) or hook type gutter profile from the same machine.

  • Page 33: Figure 20: Bead Roller Adjustment

    CHAPTER 13 HOOK ASSEMBLY (OPTIONAL) Figure 20: Bead Roller Adjustment...

  • Page 34: Figure 21: Ams Box Without Cables

    APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER COMPUTER BATCH AND LENGTH CONTROLLER The optional Batch and Length Control Computer is used to control number and length of panels that your machine produces. It uses an Encoder and Wheel assembly that runs on the bottom of the panel for measurement.

  • Page 35: Introduction

    APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER Figure 22: AMS Box With Cables Introduction Overview The AMS Controls MP465 is an industrial controller used to control cut-to-length machinery. Figure 23 shows the front panel of MP465. Figure 23: AMS Controls MP465 Controller A - 2...

  • Page 36: Manual Operations

    APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER Features The MP465 controller’s features include: • Accurate length control • Simple programming • Easy calibration Manual Operations Jogging Material • To jog material forward using the MP465, turn the jog switch on the controller to the right (clockwise).
  • Page 37 APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER original value. Push Button and Front Panel Selector Switches Shear Press [Shear] to manually activate the shear.  Note: The MP465 controller allows this switch to operate when the machine is stopped. Halt Select [Halt] to load a coil and to stop the machine Select [Run] to start the machine after a job has been programmed...
  • Page 38 APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER 4. In the Length field, up to 999 feet and 11.999 inches. 5. The controller displays the message “Pause After Job xx?” (Where xx is the job number assigned in step 1). Select: Yes to have the machine halt automatically after the selected job number is finished.

  • Page 39: Administrative Screens And Functions

    APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER 7. With the controller powered on, press [Calibration] until the screen title says “CALIBRATE-1”. The display shows you the current correction factor. Press [Clear] to begin the calibration process. 8. When the prompt “ENTER PROGRAM LENGTH” displays, enter the part length of the part you are attempting to produce.

  • Page 40: Troubleshooting

    APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER  Note: To reset the correction factor to 100% press [Clear] . When the prompt “ENTER CODE TO CLEAR TOTAL” displays; enter 1984 and press [Enter] Production Totalizer Total production of the machine is counted by the controller. You can view the production counter by pressing and releasing the [Calibration] key until the screen title displays “PRODUCTION-1”.
  • Page 41 APPENDIX A COMPUTER BATCH AND LENGTH CONTROLLER SOLUTION #2: Check condition of Main Communication Cable. Tighten cable connection or replace cable as required. SOLUTION #3: Clear memory on computer. Turn power off at computer. Turn power back on and push the #5 button while the boot screen is on. CAUTION: CLEARING THE MEMORY WILL CLEAR ANY JOBS PREVIOUSLY PROGRAMMED.
  • Page 42 APPENDIX B ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS Sheet Drawing Number Number Description FWM-380-000 Electrical Assembly – Parts List FWM-380-000 Electrical Assembly – Component Details FWM-381-000 Control Box Assembly – Parts List FWM-381-000 Control Box Assembly – Outside & Inside Views FWM-381-000 Control Box Assembly –...
  • Page 44 Parts List ITEM QTY PART NUMBER TITLE ELC-300-138 GROMMET, " ID, 1- " OD INSTALL GROMMET FAS-HC5-118 HEX HEAD CAP SCREW, 1/4-20 x 1" LG. IN MACHINE COVER FAS-HC5-278 HEX HEAD CAP SCREW, 1/4-20 x 2" LG. AS REQUIRED FAS-NUY-188 NYLOC HEX NUT, #1/4-20 FAS-SRM-207 SCREW, PAN HEAD, 8 x...
  • Page 45 SSP-340-000 ELC-400-105 SHEAR TOP OF STROKE LIMIT SWITCH ASSEMBLY RIGHT LEFT FWM-440-000, SSH-440-000, BG7-440-000, 5VC-440-000 N.O. N.O. CONTROL VALVES (HYDRAULIC COMPONENTS) N.C. N.C. 58 BRN BLU 61 SHEAR MOTOR CONTROL CONTROL DOWN ELC-400-105 ELC-400-105 ELC-400-105 PRESSURE LINE OVERRIDE SWITCH BOTTOM OF STROKE (HYDRAULIC COMPONENT) LIMIT SWITCH N.O.
  • Page 46 PARTS LIST ITEM PART NUMBER TITLE AMS-450-005 3812Y-4 CABLE AMS-450-006 3812BHNT-4 CABLE ELC-300-103 PUSH BUTTON, GREEN ELC-300-104 SELECTOR SWITCH, W/1 N.O. ELC-300-105 FUSE, 10A, 250V, TIME DELAY ELC-300-107 PUSH BUTTON, RAISED RED ELC-300-109 SELECTOR SWITCH, 2 POS,1 N.O. 1 N.C. ELC-400-018 IDEC #HW-C01 N/C CONTACT BLOCK ELC-400-019...
  • Page 47 COMPUTER HOT MELT OPTION NEW TECH MACHINERY MATERIAL LENGTH FINISH CORP. SEE BOM NONE TOLERANCES DRAWN BY PART NAME ECR NO. DATE RELEASED BY .XX = CONTROL BOX ASSEMBLY DATE .XXX = .005 06/24/04 CHECK BY REVISION PART NUMBER SHEET 1/32"...
  • Page 48 MOTOR SHEAR B.O.S. PHOTO SHEAR MOTOR P.S. UP - DN REV - FOR MOTOR 62 61 56 55 53 52 RELAY + 12V IDEC RJ1S-CL-D12 IDEC SJ1S-07L - 12V WHT/RED FORWARD WHT/RED WHT/BLK SHEAR WHT/BLK RED/BLK RELAY REVERSE RED/BLK RED/WHT IDEC RJ2S-CL-D12 IDEC SJ2S-07L RED/WHT...
  • Page 49 START -12V FEED MOTOR E-STOP T.O.S. T.O.S. QCPP LEFT RIGHT +12V N.C. N.O. N.O. N.O. N.O. LEGEND START MOTOR WIRE NUMBER QCPP PIN NUMBER START N.O. N.C. FUSE QCPP CONTACT (N.O.) MOTOR LATCH CONTACT (N.C.) REMOTE QCPP-GAS QCPP START LATCH MUSHROONM HEAD KILL SWITCH GROUND...
  • Page 50 1 6 2 6 5 E . 3 3 r d D r . S t e 4 0 | A u r o r a , C O 8 0 0 1 1...

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