Epple Maschinen PW 30 User Manual Download Page 1

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Stand 31.07.08, PW 30, PW 30 HV, Profile roll

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User manual

Profile roll

PW 30

(HV)

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Summary of Contents for PW 30

Page 1: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 1 of 50 User manual Profile roll PW 30 HV Keep for future reference ...

Page 2: ...n and warning signs 12 1 7 Safety check at the machine 12 1 8 Personal protective equipment for special work 13 1 9 Safety during the use of the machine 14 1 10 Safety during general maintenance work 14 1 10 1 Breaking and assuring the machine 15 1 10 2 Use of hoisting devices for attendance work 15 1 10 3 Mechanic attendance work at the machine 15 1 11 Accident report 15 1 12 Electricity 15 2 TEC...

Page 3: ...ilt bending device 24 4 11 Recommendations and assistance 24 4 12 Working notes 24 4 12 1 General notes 24 5 BENDING 25 5 1 Bending instruction 25 5 2 Bending of closely radiuses 26 5 3 Bending of longer work parts 27 5 4 Bending of angle iron 28 6 ROLLER SETS 29 6 1 Round material massive 29 6 2 Round material cavernous tube 29 6 3 Square massive 29 6 4 Square cavernous tube 29 6 5 U profile stra...

Page 4: ...wng 2 38 10 3 Schematic drawing 3 39 10 4 Schematic drawing 4 39 10 5 Schematic drawing 5 40 10 6 Schematic drawing 6 40 10 7 Schematic drawing 7 41 10 8 Schematic drawing 8 41 10 9 Schematic drawing 9 42 10 10 Schematic drawing 10 43 11 REPLACEMENT PART LIST 44 11 1 Replacement parts PW 30 44 12 ELECTRICITY 45 12 1 Overview electricity 45 13 REPLACEMENT PART LIST 46 13 1 Replacement parts electri...

Page 5: ...anual please observe Legal regulations for accident prevention Applicable laws and regulations The prohibition warning and mandatory labels as well as the warning notes You are liable to follow the european norms by installation operation maintenance and reparation of the machine If european norms still are outstanding you are liable to use the country specific effectual norms If necessary you hav...

Page 6: ...ll cause serious injury or death to personnel Warning Risk a danger that might cause serious injury of death to personnel Caution Danger or unsafe procedure that might cause injury to personnel or damage to property Attention Situation that could cause damage to the machine or products and other types of damage No risk of injury personnel Information Application tips and other important or useful ...

Page 7: ...wing applications This profile roll only is for rounding and bending of steel non demure nonferrous metal and non rusting steel Any other use is improper If the machine is used in any way other than as described above modified without authorisation of Epple Maschinen GmbH or operated with different process data then it is being used improperly We do not take any liabilities for damage caused by im...

Page 8: ...break the rolls and cause heavy injuries Danger for ears 85 dB A The running bending rolls can catch and contract your work wear Danger of cuts by sharp edged work parts By the maintenance and use of the machine dangers because of false use or improper maintenance may encounter you Information To avoid errors and dangers all users who are assigned with the assembly the use and maintenance have to ...

Page 9: ...e Determine clearly and irrevocably who will be responsible for the different activities on the machine operation maintenance and repair 1 4 2 Authorised personnel Warning Incorrect use and maintenance of the machine constitute a danger for personnel objects and the environment Only authorized persons may operate the machine Authorised personnel for the use and maintenance are Trained and instruct...

Page 10: ...observes the operation manual and whether it is close to the machine Check that the staff is aware of safety and dangers in the workplace and that they observe the operating manual 1 4 4 The user must Observe commands of superiors and sentinels You may not remove safety equipment during work Avoid a cant of the work part during work part feeding to the roller set Avoid contact with roller set Use ...

Page 11: ...ion can lead to danger of personnel 1 6 Safety equipment The use of the machine is only allowed with correct functioning safety devices The machine is to decommission directly if a safety device is deficient of effectless Therefor you are responsible as an operator user After response defect or falling out of a safety device the machine may not be in use until The failure cause of the failure is a...

Page 12: ...olute validation and are to observe implicitly 1 7 Safety check at the machine You are bound to check the machine at least once pro shift Announce scarcities and defects directly You have to check all arrangements Before every shift By disconnected use before every use After every maintenance Assure and check that all warning notes and signs are at the machine completely and good readable Document...

Page 13: ...hen lifting or handling pieces with sharp edges Wear safety shoes when fitting dismanteling or transporting heavy components Use ear protection over 80dB Wear closely safety suit Do not wear long hair open wear hairnet or cap Check before start of work whether the required protective is complete and intact Broken protective has to be modernised Always announce missing protective and only begin to ...

Page 14: ...dicaments Follow the using attendance and maintenance instructions in this user manual Observe the accident prevention regulations that are effective for your business Announce abnormalities and defects directly to your superior Only leave the machine after deactivation if it has stopped completely 1 10 Safety during general maintenance work Before you begin with maintenance work at the machine yo...

Page 15: ...the effective accident prevention regulations for your business 1 10 3 Mechanic attendance work at the machine Before or after attendance work Replace all protection and safety units that are especially for attendance work and activate the machine with the machine own protection and safety units Check the protection and safety units after every attendance or maintenance work about completeness and...

Page 16: ...meter minimal 1 200 mm Bending capacity square cavernous 40 x 40 x 3 mm Bow diameter minimal 1 000 mm 2 3 Machine dimensions Type PW 30 PW 30 HV Depth 480 mm 1 002 mm Total height 1 360 mm Width 990 mm Weight 191 kg 2 4 Environmental conditions Temperature range 5 35 C Air humidity 25 up to 75 2 5 Emissions The noise emission of the machine is ca 75 db A If you use more machines at one time it is ...

Page 17: ...tions for the carrier box palette Rope stops Weight Balance point Prescribed means of transport Warning If the lifting tool is not stable enough it can burst what may cause heavy or deadly injuries Check before working with lifting tool whether it is admitted for the load and undamaged Observe the effective accident prevention regulations for your business Never step under lifted loads for your ow...

Page 18: ...hine only may be lifted at the adequate areas with adequate lifting device and load rope devices Observe the balance point of the machine Observe that during lifting no add on parts ort he lacquer get damaged Machine weight PW 30 191 kg PW 30 HV 191 kg In this case the manufacturer can not assume responsibility 3 4 3 Positioning plan Observe during the positioning of the machine that the design of...

Page 19: ...dden 3 4 6 Anchored assembly For the use of a machine of this type it has to be fixed at the installation location Observe that the machine is anchored safe and orderly Assure during the anchorage that you follow the internal safety regulations Anchor the unit accordant to the condition of the ground with adequate anchor fuses or dowel screw combinations Balance asperities by shimming ...

Page 20: ...ore an acid free lubricant Lubricate all movable parts 3 5 2 Sight check manual function check Attenntion Machine may not be connected with grid Remove all transport lockings Check whether the machine has visible defects Check all mechanic components about smoothness Check all control elements about mechanic function and smoothness 3 5 3 Electrical connection The mains plug is correct pre assemble...

Page 21: ...ty of the personnel is assured The material should agree with the following claims Dry and clean oil free The diameter has to conform the information The material should have a constant degree of hardness We recommend you to buy materials of high quality The surface of the material should be flat 4 3 Electrical connection The electrical connection only may be accomplished by a qualified expert In ...

Page 22: ...cator elements are located at the following areas Machine frame Foot switch 4 5 Activating the machine Activate the machine at the main switch Release the emergency Stop control Actuate the foot switch 4 6 Deactivating the machine Let the foot pedal go or Push the emergency Stop control Deactivate the main switch ...

Page 23: ...wise direction or Let the particular actuated foot switch go The bending rolls deactivate 4 9 Adjust bending radius You have to adjust the bending radius with the back lower roll about the hand wheel at the right front For small bending radiuses you have to start first with another setting By alternate rolling to the front and back again with consistent infeed you approach to the aim measure For l...

Page 24: ...s variable runs are necessary Closely bows and full radiuses need always a few runs The using personnel is not allowed to wear wide clothes jewellery rings etc to avoid a contracting into the running machine In the case of failures you have to actuate the emergency Stop control immediately 4 12 Working notes 4 12 1 General notes Remove all unnecessary parts tool etc from the machine Assure that th...

Page 25: ...y you have to use the power that is necessary to bend the material If are too powerful you may damage the material and do not achieve the desired bending radius Pic 2 You can move the rolls forwards and back with the foot pedal Pic 3 to achieve in a few runs the correct bending radius If the bending radius becomes too large move the upper roll downwards and repeat the working actions If the bendin...

Page 26: ...re touched at the same time Observe that the material lays parallel to the bottom This position id called 0 position 3 Extract the work part from the machine 4 Readjust the pressure roll as needed but only max until the lower edge of the work part impacts the arbor middle in the 45 angle Pic 2 5 Start the machine and insert the work part 6 Repeat this cycle whenever you have achieved the desired m...

Page 27: ... PW 30 HV Profile roll Page 27 of 50 5 3 Bending of longer work parts Pic 4 If you have longer work parts for bending we advise you to use a roller block Pic 4 therewith the bending of longer work parts is facilitate a lot ...

Page 28: ... 5 4 Bending of angle iron For the bending of angle iron you have to use special rolls optional The material can not bend with the standard rolls Please have a look at our main catalogue fort he roller sets that are optional available at Epple Maschinen GmbH ...

Page 29: ...d profile rolls are turned off at radius depth Standard roller sets Rollers with overlaying flanks You achieve best results with rollers that have flanks that are lying over the radius 6 2 Round material cavernous tube Standard roller set Rollers with overlaying flanks 6 3 Square massive By default profile rolls are turned off at low depths You achieve better results with rollers that have flanks ...

Page 30: ...d 31 07 08 PW 30 PW 30 HV Profile roll Page 30 of 50 6 7 T profile straight external bow 6 8 T profile straight internal bow 6 9 Angle profile straight external bow 6 10 Angle profile straight internal bow ...

Page 31: ...scribed Forwards you may not begin with the now following works Declamp the safety screws of the rolls Detract the rolls Insert the roller sets into the accordant brackets Assemble thereby the roller sets part for part in the dismantled so that no part gets lost 7 3 Cycle Assemble new roller set After you have dismantled the roller set you can insert now the new roller set Lubricate the axes a lit...

Page 32: ...roducts Environmental protection Observe that no oil or cooling liquid attains to the bottom Please bond leaked oils and cooling liquids in accordance with the effective environmental protection instructions Interception of leakages Do not pass back liquids which accrue at the maintenance or by leakages also outside of the system into the machine or holding tanks but collect them in a separate tan...

Page 33: ...work may only achieved by qualified personnel 8 1 1 Preparation Warning Only work at the machine if the mains plug is disconnected and secured against resetting Add a warning sign to prevent accidentally resetting 8 1 2 Recommissioning Before every use it is necessary to do a safety check Execute the safety check at the machine like described at point 1 7 Warning Assure before starting the machine...

Page 34: ...ed directly Check the function of the safety switch equipment 8 2 3 Weekly work Well cleaning of the machine and remove chip rests Clean the rolls Dismantle the rolls Open the housing and clean the internal room and the adjusting spindle Check the condition of the rolls defect rolls have to be replaced directly Check the function of the safety switch equipment 8 2 4 Monthly work Check the blameles...

Page 35: ...ersonnel the advices in the operation manual have to be observed strictly The Epple Maschinen GmbH does not assume accountability for defects consequential damages and possible disruptions in operation by improper maintenances and non observance of the operation manual More conditions for the reparation and correct maintenance are Adequate and technical blameless tool Only original replacement par...

Page 36: ...ck axes Unload axle bearing Change axle bearing Machine only runs in one direction Foot switch cable defect Renew control element cable Gate defect Replace gate Work part is not bend constantly Bending roller adjustment false Approach in small Steps to the requested bending radius Bending rolls do not run centric Use roller set with exact bore Work part twists during bending False roller set Use c...

Page 37: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 37 of 50 10 Exploded drawing 10 1 Schematic drawing 1 ...

Page 38: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 38 of 50 10 2 Schematic draiwng 2 ...

Page 39: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 39 of 50 10 3 Schematic drawing 3 10 4 Schematic drawing 4 ...

Page 40: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 40 of 50 10 5 Schematic drawing 5 10 6 Schematic drawing 6 ...

Page 41: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 41 of 50 10 7 Schematic drawing 7 10 8 Schematic drawing 8 ...

Page 42: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 42 of 50 10 9 Schematic drawing 9 ...

Page 43: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 43 of 50 10 10Schematic drawing 10 ...

Page 44: ...6008 29 Nut 103 Gasket ring 30 Feeder guidance 104 Gasket ring 31 Arbor acceptance 110 Ground plate food switch 32 Arbor 111 Bolt 33 Support bush 112 Auflage 34 Bearing cup 113 Screw M5x8 35 Needle 114 Screw M5x12 36 Scale 115 Screw M5x12 37 Bolt 116 Shim 38 Plate 117 Shim 39 Bearing cup 118 Divisor disc 40 screw M8x40 119 Rod 41 Circlip M12 121 Bolt 42 Feather key 122 Plate 43 Locking ring 123 Pl...

Page 45: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 45 of 50 12 Electricity 12 1 Overview electricity ...

Page 46: ...No Model Size Pcs 74 Motor 207 Fuse base 120 Foot switch 208 Safety cap 139 Control element 209 Safety 200 Control panel 211 Safety 202 Earthing terminal strip 212 Terminal strip 203 Terminal strip 221 Main switch 204 Overcurrent protection relay 222 Emergency Stop control 205 Transformer 223 Emergency Stop control 206 Gate 225 Feeder ...

Page 47: ...Stand 31 07 08 PW 30 PW 30 HV Profile roll Page 47 of 50 14 Circuit diagram 14 1 Circuit diagram ...

Page 48: ...With the buy of the machine you are bound to our product follow up during the use This duty is assigned to third customers after a resale You are liable to inform third customers We would be grateful if you could send us the following information For example nearly accidents at the machine Accidents at the machine Empirical value which can be or are important for users Elevated abrasion of expenda...

Page 49: ...lares herewith that the metal profile rolls PW 30 and PW 30 HV agree with the following claims EN60204 1 And work accordant to the following guide lines EG machine guide line 2006 42 EC 91 368 EWG 93 44 EWG 93 68 CEE Sound level guide line 86 188 EWG Low voltage guide line 73 23 EWG The profile rolls PW 30 and PW 30 HV agree with the CE norm Karsten K S Epple business manager Wiesensteig 31 07 200...

Page 50: ...ing Defects in paint work Accessories corresponding to user manual existing User manual existing Elektric corresponding to examine statement IO NIO note Plug at feeding line mounted checked Motor run at checking device checked Electric control switch checked Emergency Stop control switch checked Earth conductor test accomplished Mechanic corresponding to examine statement IO NIO note Mechanic cont...

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