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Engel 800 Series Installation, Operation & Maintenance Manual

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ENGEL 800 SERIES
ROLLFORMER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manual-MN031407
March 2007

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  • Page 1 ENGEL 800 SERIES ROLLFORMER INSTALLATION, OPERATION & MAINTENANCE MANUAL Manual-MN031407 March 2007...
  • Page 2 Furthermore, ENGEL INDUSTRIES reserves the right to make changes to any products herein, at any time, to improve reliability, function, or design. ENGEL INDUSTRIES does not assume any liabilities arising out of the application or any use of any product described herein, neither does it convey any license under its patent rights nor the rights of others.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SAFETY SECTION LOCKOUT GUIDE ASSEMBLY DRAWINGS (Back of Manual) ELECTRICAL SCHEMATICS (Back of Manual) Section/Page 1. INTRODUCTION........................1-1 A. INSTALLATION ..........................1-2 Unpacking The Machine ....................1-2 B. SAFETY ............................. 1-2 Safety Precautions (Before Starting The Machine)............1-2 Safety Precautions (While Operating The Machine)............1-3 2.
  • Page 4 Table 4-4. Lubrication Schedule....................4-5 Table 4-5. System Lubrication Points..................4-5 Table 4-6. Inspection Schedules ...................4-7 LIST OF FIGURES Figure 1-1 Engel 800 Series Rollformer ................1-1 Figure 2-1 Rollformer Assembly....................2-1 Figure 2-2 Typical Entrance Guides (HB-825S Shown)............2-2 Figure 2-3 Triplex Entrance Feed Guide ................2-2 Figure 2-4 Roll Gap Adjustment Components...............2-3...

  • Page 5: Introduction

    Engel equipment. It is your responsibility to maintain and operate this equipment in strict compliance with all applicable laws, safety regulations, and the manufacturer’s recommended procedures.
  • Page 6 10. Post a list of names, addresses, and phone numbers of physicians and others who are to be called in emergency situations. CUSTOMER'S RESPONSIBILITIES There are certain hazards associated with the operation of any equipment or system of machinery that are impractical, if not impossible, for equipment suppliers to safeguard. The user must address these hazards and be responsible for providing guards or barriers for establishing appropriate work procedures and for training personnel in the safe operation of that equipment.
  • Page 7 WARNING LABELS Warning and safety related informational labels are placed on the Engel Industries Industries’ equipment at strategic points. It is important that these labels not be removed, covered, hidden, or defaced. The purpose of these labels is to alert personnel to potential personal injury hazards or other direct or indirect safety concerns.
  • Page 8 Engel Industries Industries. Replacement and maintenance parts should be equal to original equipment. Use of other parts may result in unsafe operating conditions. If there is a question as to the suitability of a part, Engel Industries should be consulted.
  • Page 9 ENGEL has conducted hazard evaluation and risk analysis studies for their products. Safe guards installed on the equipment are there for a reason. BEFORE EQUIPMENT IS PLACED INTO SERVICE, ALL SAFE GUARDS OR DEVICES MUST BE IN PLACE AND PROPERLY ADJUSTED.
  • Page 10 2. POINT OUT EXAMPLES of each type of hazard on the actual equipment the individual operates or works around. 3. EXPLAIN HOW TO AVOID HAZARDS in the individuals work environment. 4. GIVE a copy of the HAZARD REMINDER sheet to each individual. Safety is everyone’s business! SAFETY - 6...
  • Page 11 SAFETY FIRST THINK NIP POINT WHEN ONE OBJECT ROTATES NEAR ANOTHER, IT CAN PULL YOU IN and CRUSH YOU PINCH POINT WHEN ONE OBJECT MOVES CLOSER TO ANOTHER, IT CAN CUT or PINCH YOU. MOVING EQUIPMENT and COILS CAN KNOCK YOU OFF BALANCE or CRUSH YOU STRIP EDGES and ENDS CAN CUT or STRIKE YOU.
  • Page 13 LOCKOUT GUIDE 1. LOCKOUT GUIDE A. INTRODUCTION An essential element of a comprehensive safety program includes the development and use of a written hazardous energy lockout procedure. The lockout procedure establishes the minimum requirements for the lockout of hazardous energy sources using an energy-isolating device whenever maintenance or service is performed on the processing line.
  • Page 14 (4) Lockout The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed. (5) Tagout The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
  • Page 15 • Contact Safety Manager for review of new equipment prior to releasing the equipment to production. (4) Affected employees shall: • Notify one of the following departments for an authorized employee lockout whenever servicing or maintenance is needed: Maintenance Die Setters Press Operators Engineers and Technicians •...
  • Page 16 • Shut the machine down using normal operating means (stop button). Operate (shut off, close, block, etc.) all of the energy-isolating devices. Lock out the energy-isolating devices with the assigned red padlock(s). Mechanical power presses will have the lockout procedures posted in a binder in each department supervisor’s office, listed by asset number.
  • Page 17 • The incoming crew will then verify lockout using all procedures before replacing the departmental locks with their own or using lock box procedures. Contractors working in the company plant must have lockout procedures that meet or exceed the standard. •...
  • Page 18 • There is a change in their job assignments. • There is a change in equipment, machines, or processes that present a new hazard. • There is a change in energy control procedures. • Periodic inspection reveals or there is reason to believe that there are deviations from this policy caused by inadequate knowledge of the procedure.
  • Page 19 Department locks will be numbered and identified by department and kept in: • The department office in a lock bank. • In the area on a lock bank. • In a cabinet. 5. Locks will be purchased by departments (by Managers ONLY). 6.
  • Page 20 • The person is not exposed to unexpected energization, start-up or release of stored energy. 2. When servicing, testing, and maintaining equipment in which: • The unexpected energization of machines or equipment COULD CAUSE INJURY OR DEATH. • The unexpected start-up of machines or equipment COULD CAUSE INJURY OR DEATH.
  • Page 21 • The key to that identified departmental lock(s) will then be placed into an identified lock box. • All personnel associated with the lockout will then secure the identified lock box with their personal locks. (13) Department lock banks All departments will maintain a “lock bank”. A lock bank is a storage area for identified departmental locks.
  • Page 22 (17) Retraining 1. When there is a change in job assignment, machines, equipment, or processes that present a new hazard or there is a change in the energy control procedure. 2. Shall re-establish employee proficiency and introduce new or revised control methods and procedures as necessary.

  • Page 23: Figure 1-1 Engel 800 Series Rollformer

    The 800 Series Rollformer is equipped with a 5 HP motor with a variety of voltages available. Line speed is set at 90 FPM and the entire unit is backed up with Engel’s one year factory warranty.

  • Page 24: Installation

    Answers to questions regarding site preparation and other technical assistance is available free of charge via telephone between the hours of 8 AM and 4:30 PM CST Monday through Friday by calling the Engel Customer Service Department at 314-638-0100. (1) Unpacking The Machine When the machine arrives, inspect it carefully before accepting the shipment.

  • Page 25: Safety Precautions (While Operating The Machine)

    Be alert for loose, worn, or broken parts. Do not attempt to operate the machine with such parts present, or if the machine is making unusual noises or actions. Be sure that this manual is kept near the machine so the operator can refer to it when necessary.
  • Page 26 Page 1-4 March 14, 2007...

  • Page 27: System Overview

    2. SYSTEM OVERVIEW A. ROLLFORMER The Engel 800 Series Rollformer utilizes 8 forming stations to produce the desired profiles. It is powered by a 5 HP motor, with a production rate of approximately 90 feet per minute. The forming rolls were factory pre-gapped and should require little or no adjustment. The pre- gap settings allow the production of various gauges, without resetting any roll gap.

  • Page 28: Triplex Outboard Feed Guide Option

    Figure 2-2 Typical Entrance Guides (HB-825S Shown) (2) Triplex Outboard Feed Guide Option If your 800 Series is equipped with Triplex outboard tooling, it will come with a multi- position entrance feed guide. This guide allows a variety of profiles to be formed without manually repositioning the entrance feed guides.

  • Page 29: Factory Roll Gap Settings

    (3) Factory Roll Gap Settings The forming rolls were factory pre-gapped and should require little or no adjustment. The pre-gap settings allow the production of various gauges, without resetting roll gap. All 8 stations are factory gapped. Each set of four forming stations is equipped with four Tensioning Assemblies (Items A-D) and four Roll Gapping Assemblies (Items E and F).

  • Page 30: Roll Gap Chart

    Figure 2-5 Roll Gap Locations 6. This may take several adjustments to achieve the desired results. 7. Once the adjustment has been made retighten all Jam Nuts (F) on each Tensioning Assembly and then confirm proper gap. 8. Loosen Locking Jam Nut (B) on each Tensioning Assembly. 9.

  • Page 31: Slitter Attachment (Option)

    Drive or S cleats. This unit is mounted to the top of the 800 series with a chute located between the slitter knives and the first set of forming rolls. This allows the strip to go from the slitter directly into the forming rolls, which reduces material handling.

  • Page 33: System Controls

    3. SYSTEM CONTROLS This section describes the operational controls for the rollformer. The only control of the Engel 800 Series is a single On/Off rocker switch. This switch is used to start and stop the forming rolls drive motor. (1) ROLLFORMER START/STOP SWITCH A rocker style switch is used to start and stop the rollformer drive motor.
  • Page 34 Page 3-2 March 14, 2007...

  • Page 35: Maintenance

    4. MAINTENANCE A. TORQUE VALUES FOR GENERAL ASSEMBLY The torque chart value (Table 1 and 2) is provided for reference when performing general assembly of various components. These values should be used only if torque values are not otherwise specified for a particular assembly. Refer to the associated assembly drawings for assemblies or other component assemblies that may require special torque specifications.

  • Page 36: Table 4-1. Metric Bolt And Cap Screw Torque Values

    Table 4-1. Metric Bolt And Cap Screw Torque Values Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 size Lubricated* Dry* Lubricated* Dry* Lubricated* Dry* Lubricated* Dry* Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft 11.5 14.5 1075 1150 1075 1350 1000...

  • Page 37: Table 4-2. Unified Inch Bolt And Cap Screw Torque Values

    Table 4-2. Unified Inch Bolt And Cap Screw Torque Values Grade 1 Grade 2 Grade 5, 5.1, or 5.2 Grade 8 or 8.2 size Lubricated* Dry* Lubricated* Dry* Lubricated* Dry* Lubricated* Dry* Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft Lb-ft 13.5 12.5 5/16...

  • Page 38: Servicing

    B. SERVICING (1) Lubricant Recommendations / Specifications To ensure that the system is kept in a correct operating condition, it must be inspected and maintained on a regular basis. Proper cleaning and/or replacement of filters, the periodic lubrication of bearings, bushings, chains and other moving friction and wear generating points will prevent damage to or failure of the unit, and provide optimum performance.

  • Page 39: Table 4-4. Lubrication Schedule

    2. When using a low pressure grease gun, lubricate only to the point of grease starting to come out of the edges of the seals, etc., of the item being lubricated. 3. Do not over lubricate chains. Chain drives should not be lubricated to the point that oil is "flung"...

  • Page 40: Tooling Replacement

    Engel Service Department. The Engel representative will need the number stamped on the face of the roll(s) to ensure the correct replacements are ordered and shipped. The Engel Service phone number is (314)-638-0100 and the normal hours of operation are M- F 8-4:30 CST.

  • Page 41: Preventive Maintenance

    D. PREVENTIVE MAINTENANCE A periodic inspection schedule should be established and maintained. A suggested inspection/check schedule is provided in Table 4-6. The criteria listed meet the minimum requirements necessary to ensure safe reliable service under normal operating conditions. It should be modified as required to meet varying operating and environmental conditions. Table 4-6.
  • Page 42 Page 4-8 March 14, 2007...

  • Page 43: Assembly Drawings & Electrical Schematics

    F. ORDERING PARTS A Parts Order form is provided for your convenience. Photocopy the form for shop use. Fill out all required spaces. Parts orders may be placed by telephone, or may be faxed to Engel Industries. G. RETURNS...

  • Page 44: (A) Warranty Claim Approved

    Engel, freight prepaid, for inspection and warranty determination. • Purchased parts (items not manufactured by Engel) are warranted by their vendor or manufacturer. Engel is not liable for this warranty, but will, for the convenience of our customers, process such warranty claims to the vendor. •...

  • Page 45: (B) Warranty Claim Disapproved

    A Warranty Inspection Report is prepared and mailed/faxed/or emailed to the customer. This report requests part disposition from the customer. The part will be held at Engel for 30 days. Within that time frame the customer must select to have the part: •...
  • Page 46 Page 4-12 March 14, 2007...
  • Page 47 CUSTOMER PARTS ORDER FORM INSTRUCTIONS Please fill out the form with the information requested. Use extra sheet if additional parts are required. Fax to Engel Industries and we will process your order. PARTS ORDER INFORMATION Customer Name: Purchase Order No.:...
  • Page 48 Page 4-14 March 14, 2007...
  • Page 49 Warranty denied parts will only be held by Engel for 30 days from the date of customer notification. After that date, unless instructed otherwise, the part will be scrapped.
  • Page 50 Page 4-16 March 14, 2007...

  • Page 51: Figure 4-1 Hydraulic Symbols Used On Assembly Drawings

    Figure 4-1 Hydraulic Symbols Used On Assembly Drawings March 14, 2007 Page 4-17...

  • Page 52: Figure 4-2 Electrical Symbols Used On Assembly Drawings (Sheet 1 Of 2)

    Figure 4-2 Electrical Symbols Used On Assembly Drawings (Sheet 1 of 2) Page 4-18 March 14, 2007...
  • Page 53 Electrical Symbols Used On Assembly Drawings (Sheet 2 of 2) March 14, 2007 Page 4-19...
  • Page 54 Page 4-20 March 14, 2007...

  • Page 55: Assembly & Electrical Drawings

    H. ASSEMBLY & ELECTRICAL DRAWINGS The Assembly and Electrical drawings are furnished in this section for troubleshooting, parts ordering and component identification. Please use these drawings when replacement parts are required to help speed up the ordering process. March 14, 2007 Page 4-21...
  • Page 56 Page 4-22 March 14, 2007...

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