Nantong Rebest Technology Co.

, Ltd
Factory Add: 99#, Zhongba Middle Road, Haian Town, Nantong City, Jiangsu, China
Export Director: Ms. Cindy Ding Mob./ WhatsApp/ Wechat: +86-15996612182
Fax:+86-0513-88685226 E-mail:sales@rebestmachine.com

W12 Series Operation Manual

4 Rolls Plate Bending Machine
 Operation Manual

CATALOG
1. INSTALLION......................................................................................................................................... 1
1.1 TRANSPORT................................................................................................................................1
1.2 UNLOADING AND HANDLING............................................................................................... 1
1.3 RECEIVING................................................................................................................................. 3
1.4 INSTALLATION.......................................................................................................................... 4
1.5 FOUNDATIONS...........................................................................................................................5
1.6 LEVELLING.................................................................................................................................6
2. START UP...............................................................................................................................................6
2.1 PRELIMINARY OPERATIONS.................................................................................................. 6
2.2 ELECTRIC WIRING AND START-UP....................................................................................... 8
2.3 MOVEMENTS........................................................................................................................... 10
3.SAFETY.................................................................................................................................................13
3.1 ALLOWED/FORBIDDENOPERATIONS.................................................................................13
3.2 SAFETY MEASURES............................................................................................................... 15
3.3 CONTROL DEVICES................................................................................................................ 15
3.4 SAFETY DEVICES....................................................................................................................16
3.5 MACHINE PERSONNEL.......................................................................................................... 18
4.MAINTENANCE INSTRUCTIONS.....................................................................................................20
4.1 HYDRAULIC DEVICE..............................................................................................................20
4.2 PLANETARY REDUCERS........................................................................................................20
4.3 HYDRAULIC COMPONENTS................................................................................................. 21
4.4 MACHINE CLEANING.............................................................................................................21
5. GENERAL USE INSTRUCTIONS......................................................................................................22
5.1 INTRODUCTION.......................................................................................................................22
5.2 PLATE PREPARATION............................................................................................................. 23
5.3 WORKS MEASURES................................................................................................................ 25
6.MAIN APPLICATIONS........................................................................................................................ 30
6.1 PRE-BENDING.......................................................................................................................... 30
6.2 ROLLING DEFECTS.................................................................................................................38
7. ELECTRICAL CONTROL SYSTEM DESCRIPTION....................................................................... 43
7.1SECURITY EXPLAIN................................................................................................................ 43
7.2 MACHINE OPERATION...........................................................................................................43
 Operation Manual

1. INSTALLION
1.1 TRANSPORT
Transport the machine (and its components) with
maximum care and attention, always and only in
closed
containers or with “open top” feature avoiding thus
contact with dust, water, or smoke.

1.1.1. The machine must be laid over wooden tables and

well levelled (usually the bottom of trucks or containers
already offers this possibility). The motors box must be
placed close to the driver’s cab of the truck.

1.1.2. Should a consolidated transport be the case, it is

FORBIDDEN to put anything else over, next to or in
any
other part of the machine, that must travel in a completely
free zone of the truck/container.

1.1.3. The machine must be duly fastened and anchored,

in order to avoid movements during transport. Avoid
at
all times sudden stops, strong vibrations and non paved
roads.

1.1.4. Special attention must be paid to the eventual

remote control boards, which contain quite fragile
electrical and electronic devices.

1.2 UNLOADING AND HANDLING

Machine’s unloading and handling are dangerous

operations and must be done by skilled personnel,
observing carefully all safety regulations for this kind
of work, thus avoiding damages to people and/or goods.
Upon its arrival to destination, unload the machine from
the container or truck observing the following
precautions:

1.2.1. Firstly, unload any eventual disassembled

component (Vertical Supports or Side Supports,
Ejector, Table, etc);
1.2.2
1.2.2. When lifting the machine always use
appropriate and certified tools having an even or higher
lifting capacity than the weight to be lifted (1.2.2.).

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 Operation Manual

ATTENTION: NEVER USE CHAINS OR STEEL

CABLES in order not to damage the rolls surface.

1.2.3. Using the appropriate stripes, place it in

between the top and bottom roll (1.2.3.1) and never in
other places, that would represent a potential source of
damage. Only in case the 2 central rolls (upper and
lower roll) are too close to each other, preventing the
stripe to be slipped in between, then proceed as shown
in 1.2.3.2)

1.2.4. In order to have a safe transport, the tilting

support MUST be blocked by appropriate clamps
(1.2.4)

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 Operation Manual
1.2.5. ATTENTION: when using two stripes
NEVER place them too far apart from each other, in
order to avoid sudden movements when lifting. (1.2.5)

1.2.6. Large and medium size machines, equipped

with special lifting points, must be handled by means of
steel bolts and cables (1.2.6)
1.2.7. When the machine is shipped over a
supporting platform with a closed crate or box, it is
possible to lift it from below by using a forklift, placing
the forks close to the points indicated.

When moving the slinged machine, always do it at a

very low speed and avoid sudden
accelerations/decelerations in orden not to
unbalance the cargo.

1.2.8. The weight and the lifting modality will be

indicated on the packing.

1.3 RECEIVING

Almost all machines are shipped assembled and ready

for use
at their destination.
The load was performed by the manufacturer with maximum
care (the carrier acknowledges to have received it in perfect
condition, by signing the shipping documents).

If at destination the machine should present any damage

(cracks, oil leakages, etc.) most likely occurred during the
transport, make a formal complain as indicated
hereunder:
- on the shipping documents that will be presented by the
carrier for acceptance;
- sending to the carrier a registered letter with a
comprehensive report on the damages within 48 hours
(with a copy via fax to the manufacturer, for information
only)

Any eventual claim for damages must be addressed ONLY to

the carrier (with a copy via fax to Promau, for information
only).

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 Operation Manual

1.4 INSTALLATION

1.4.1. The installation of the machine requires a stable

floor, leveled and rigid to avoid any deformation or
vibration to the base of the machine (1.4.1).
Lacking these requirements, it is necessary to build a
solid reinforced concrete foundation according to the
indications contained in the following paragraph 1.5.

1.4.2. Access to the bending machine must be

provided on all 4 sides:
- 1 metre (40”), at least, behind the motors box.
- A front access of at least 1,5 x rolls length in
order to allow the extraction of closed cylinders
(1.4.2.1)
- On the sides and above the machine a Y variable
dimension relative to the linear developments of
the sheets to be rolled, of the diameters to be
obtained and the sheet introduction side (1.4.2.2).

N.B. The space occupied by the parts while been

rolled must be defined and protected by the end

user, avoiding people to enter such area while the

machine is running. (see chapter 3 on safety).

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 Operation Manual

1.5 FOUNDATIONS

1.5.1 Even though most of the working stresses could be

beard by the machine’s structure, foundations are
nonetheless necessary if the existing floor shouldn’t be
adequate. Foundations are also required for medium and
large machines, and when a pit is necessary.

A solid concrete foundation should be built observing

the
following sequence:

-A- Prepare the anchor screws according to the holes

on
the machine’s base, their guides and some metallic
levelers.

-B- Provide foundation hole

-C- Reinforce the foundation

-D- Place anchor screw guides

-E- Pour high resistance concrete and fill up the

foundation

-F- Level the concrete, create the support surface,

remove
screw guides and place the support plates

-G- Lift the bending machine above the foundation

-H- Lower the machine on the foundation (assuring

the
anchor screws will pass through their holes)

-I- Finally fill up with cement (class Rbk 250

3,550PSI;
250Kg/cm2 or similar) the screw holes and allow
time for it to dry up.

ATTENTION: FOR MEDIUM AND LARGE SIZE

MACHINES SEE THE DETAILED DRAWINGS
SUPPLIED BY THE MANUFACTURER
FOR

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 Operation Manual
EXECUTING AN APPROPRIATE FOUNDATION
1.6 LEVELLING

Tighten the anchor screws and, if necessary, use

levelling plates under the screws.

For levelling use a lifting jack or another lift ONLY

under the appropriate wings of the machine’s base (or
under it) and at NO OTHER point of the machine
itself.

The planarity control must be performed using a

precision level measurer. The axes to be verified are:

The two sides of the machine: verify that they

are perfectly aligned between them (1.6.1).
Should this not be the case, add levelling
plates and restore alignment (fundamental
conditional for an appropriate use of the
machine).
- Top roll in longitudinal axis : place the level
measurer on the centre of the roll along the
axis of the motors box/tilting support (1.6.2),
once the machine is turned on to be sure that
the roll is completely in its upper position.
- Side rolls in transversal axis: place the level
measurer at the end of the side rolls, close to
the frame (1.6.2)
2. START UP

2.1 PRELIMINARY OPERATIONS

2.1.1. Fill up (filtering) with the suitable oil, till level

(A1),
the hydraulic unit tank (2.1.1-A)

Note: the use of hydraulic oil

L-HM46 # anti-wear hydraulic oil (Northern)
L-HM68 # anti-wear hydraulic oil (South)

Oil cleanliness: ISO19/16, the system working

temperature: 30 ~ 60 ° C

2.1.2. The reducers (2.1.1-B) and the eventual brake

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 Operation Manual
have
been already filled up with the suitable oil by the
manufacturer. To check the level, unscrew the taps on
the
reducers, or (where existing) from the transparent oil
level
indicator.

2.1.3. Use the following suitable suggested oils (or

correspondent of other brands):

OLEO ROOM HYDR REGULATION

DYNA TEMPERATURE AULIC
MIC OIL
UNIT Min/max Min/max ESSO ISO ISO DIN
℃ ℉ 3448 6743 51524
20/40 68/104 NUTO VG68 HM HLP
H68
5/25 40/75 NUTO VG32 HM HLP
H32
-5/20 20/65 INVAR VG22 HV HLP
OL 22
REDUCERS ESSO Viscosity ISO VG 150
EP 150
LUBRICATORS ESSO EP NLGI 2
MULTI-
PURP
OSE
CREAS
E(MOL
Y)

WARNING: Unsuitable oil could give problems to

the
correct operation of the machine.

2.1.4. Remove the protective oil or film from the surface

of
the rolls. It is advised to re-protect the rollers with the
oil in
case the machine will not be used for long time.

2.1.5. For transport safety, the end yoke can be locked

by a
bracket. Remove it before wiring (SEE.1.2.4).

2.1.6. Remove the eventual motor box panel to check

the
sense of rotation of the pumps motor in the following
starting phase.

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 Operation Manual

2.2 ELECTRIC WIRING AND START-UP

2.2.1. NEVER wire the machine prior to oils re-filling.

The
machine wiring has to conform to all the safety
regulations.
The power cable must enter the control board from the
appropriate outlet, and must be locked by a rope-gland
before starting the machine.

In machines where it is envisaged, connect the electric

socket plug directly on the electric panel.

For the electric wiring, follow carefully the indications

on the machine’s electrical diagram. The door of the
electric board can be opened only if the main switch is
in the “OFF” position.

2.2.2 Check carefully the right voltage on the

transformer and follow the safety standards.

2.2.3. On the remote console, the switching on of the

digital
readouts indicates the start up of the machine (then the
correct wiring).

2.2.4 On the front console, in addition to manual levers

and the electric joysticks , the red
emergency stop button is always present .

2.2.5. If there isn’t any active emergency status, in

manual
machines, rotating the main power switch on the electric
board from position OFF to ON, the electric motor is
directly activated. If the motor wouldn’t start, it’s
necessary to reset the emergency switch on the
emergency rope, putting it in its working positions.

In machines equipped with NC, if the emergency red

light
on the front console is off, it is possible to start up the
electric motor by moving one of the joysticks.

2.2.6. If the red light on the front panel is on, (on the
machines equipped with a NC) or the digital readouts
are
off indicate that there is an emergency status, and the

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 Operation Manual
machine can’t be started up.

To allow the machine to be re-activated, it is necessary

to
verify:
a - the position of the red emergency button;
should it be pressed, lift or rotate it clockwise (there is
an
arrow on the emergency button that shows the direction
towards which to rotate it to deactivate the emergency
status.
After having been turned, the button will return to its
upward position.

b – the position of the limit switch on the emergency

rope: if blocked, put it on its standard position

c – the emergency rope should be well pulled. If loose,

stretch it using the stretchers placed at the end of the
rope.

d – The position of other eventual emergency buttons

placed on the front console.

2.2.7. In case of remote console with NC, after having

reset
the emergency statuses, it is necessary to press the blue
button placed on the console to reset the alarm messages
on
the operator panel and switch off the red light.

2.2.8. The start up of the electric motor must be done

carefully, as follows:
Turn on the motor only for a very short time (less
than a
second) just to check if the fan turns in its arrow
direction. If so, the machine can be permanently
switched on.

If this is not the case, STOP immediately, switch off

the
machine and the electric line and invert two of the three
wiring phases, then check again if the fan turns in its
arrow
direction.

WARNING: Be extremely quick and careful; as

turning
in the wrong direction, even for only a few seconds,
may
permanently damage hydraulic pumps.

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 Operation Manual

2.3 MOVEMENTS

2.3.1. All controls are set on the console. There are three
console types:

A: On the rear side of the machine, fixed on the motor

side.

B: Front pivoting

C: (usually on machines with electrical-valves) remote

type, linked to the machine with an electric cable;
movable on wheels.

2.3.2. The console enables the standard controls of

operated:

- rolls raising and lowering

- rolls rotation (to drive the plates)

- machine opening and closing (End yoke)

- the accessories, if installed, as:

- side rollers tilting (for conical rolling);

- vertical and side supports raising and lowering;

- conveyor, feeding table, ejectors, NC.

For further information about controls, see chapter 8

“Controls and commands”

2.3.3. ROLLS MOVEMENTS

- Upper roll. (S)

During the working phase, it’s horizontally fixed. (2.3.3.2).

It is powered by a hydraulic motor, coupled with a high-

efficiency reducer, directly set on the roll’s shaft. (2.3.3.1).
In some cases – e.g. interchangeable roll with reduced
diameter - it can be idle; being set on almost friction-free
bearings, it is however easily driven by simple contact with
the plates.

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 Operation Manual
On some sizes, it can be hydraulically tilted at the end of
the rolling procedure, to allow the shell removing.

- Lower central roll (P)

It moves vertically and it’s hydraulically powered.

(2.3.3.2).

When raising, it pinches the plate against the top roller

allowing an easy control on the whole rolling cycle. The
pinching pressure can be easily preset and reduced if
rolling soft or light materials avoiding scratches or
lamination.

When lowering, it releases the shell allowing its removal

from the machine.

It is powered by a hydraulic motor, coupled with a high-

efficiency reducer, directly set on the roll’s shaft. (2.3.3.1)
on direct axes (on some models it could be idle, easily
driven by simple contact with the plate, or powered by a
hydraulic motor). It can be manually tilted for the
accurate
parallel adjustment with the upper roller.

In machines with a conical working device, they can be

easily and quickly tilted hydraulically to allow an easy
guiding and driving of the conical plate while
calendering.

C/D Two lower roller (X-Y)

They move vertically, upon hydraulic command.

(2.3.3.2)

When raising, they bend the plate at the required

diameter.
The rotation on their axis is idle; set on self-aligning,
high
efficiency roll bearings, they are friction-free and easily
driven by simple contact with the plate. On some
models
these rollers are powered by a hydraulic motor.
(2.3.3.1).

They can be manually tilted for the accurate parallel

adjustment with the upper roll in machine with
mechanical
parallelism (ABS). In case of EPS (Electrical parallelism
system) the description is on chap. “CONTROLLS

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 Operation Manual
AND
COMMANDS”

In machines with a conical working device, they can be

easily and quickly tilted hydraulically, to facilitate
conical
works.

2.3.4. The machines can have different speeds:

- Steep-les variable speed depending on the action set

on
the joystick: more drive, faster speed;

- two speeds (or more) selectable by the operator by

means of a switch on the console.

On some machines a device converts automatically the

speed from fast to slow, if the load required by the plate
raises during calendering.
For further information refer to chapter 8 (Controls and
commands).

2.3.5. The pressure gauges, are set on the front console

(see chapter 8 - Controls and commands), or on the front
frame
if NC controlled, with remote console on wheels.

2.3.6. The hand wheel valve is set on the front console

or
on the front frame if NC controlled, with remote console
on wheels. (see chapter 8 - Controls and commands)
It adjusts the plate’s pinch pressure, between the two
central rolls.

By turning this valve counter-clockwise, the pinch

pressure
drops, by turning it clockwise the pinch pressure raises.

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 Operation Manual

3.SAFETY
3.1 ALLOWED/FORBIDDENOPERATIONS
3.1.1. A bending machine is designed to cylindrically or
conically bend, steel plates, profiles or other metallic
materials. This result is obtained by introducing the
material to be worked among the rolls and forming it by
moving and rotating the rolls

3.1.2. This process includes 4 main phases:

1 - Loading the plates into the machine
2 – Plates rolling
3 - Opening the end yoke
4 – Finished product unloading

3.1.3. ALLOWED OPERATIONS

Phases 1-2-3 and 4 are usually managed by only one
operator who stands in front of the control board of
zone “A” (3.1.3).

In the rolling cycle (phase 2 and 3), the

absolute prohibition in any person for any
reason at the "B".

It is ABSOLUTELY FORBIDDEN to any person to

stand, for any reason, in zone “B” during the rolling
cycle (phases 2 and 3).
ONLY during the loading and removing phases
(NEVER WHILE ROLLING) the operator or other
persons can stand in zone B.

The plate must NEVER be left in a critical position, so

as to slip back or forward.

In case it is needed to set the pressure, to reposition the

plate, to measure the rolled shell by templates or in case
of any other need to have access to the zone “B” or “C”
during the rolling phases 2 or 3, it is ABSOLUTELY
REQUIRED that the machine BE SWITCHED
OFF, or powered, but absolutely STOPPED IN
SAFETY CONDITION.
While checking the rolling diameter the operator should
remain in front of the shell; never on its side.

3.1.4. FORBIDDEN OPERATIONS

The machine must not run without the direct

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 Operation Manual
surveillance of the operator. No operations that should
need two operators can be executed.

It is ABSOLUTELY FORBIDDEN to any person

for any reason to stand in zones “B” and “C” (3.1.3)
DURING THE ROLLING CYCLE (phases 2 and
3).

This restriction is IMPERATIVE in the first rolling

phase, when the flat plate is pinched, on its edge, by the
pinch rolls and starts being bent by the forming rolls
(RISK OF PLATE FALLING DOWN).

It is forbidden to perform any maintenance intervention

if the machine is powered. Perform it only with
machine completely switched off.
Eventual interventions to the “C” zone for set-up,
rollers or parallelism checks, or any other reason ARE
ABSOLUTELY FORBIDDEN if the machine is
running; they are allowed ONLY with the machine
STOPPED IN SAFETY CONDITIONS, and can be
done
EXCLUSIVELY by the qualified operator.

All the adjustment and/or maintenance operations on

the machine MUST BE DONE WITHOUT THE
PLATE, with the machine empty, and with all the
movable devices kept at their lowest position, with
lower control stop, in relation to the rollers (after
having place them horizontally if they were tilted), as
well as the eventual side or vertical supports.

The closed shell removal must be done by keeping its

opening in the lowest position possible, and slinging it
at 180° of its opening.

3.1.5. MAINTENANCE

The features allow all the ordinary and particular

maintenance operations (in reality very few) to be made
with the machine completely switched-off. For the
start-up and the eventual further set-up, all of them
remain valid.

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 Operation Manual

3.2 SAFETY MEASURES

While rolling, there are some phases in which the plate

could fall out of the machine and pose a risk for people.

When one of the two edges of the plate is too near

to the tangent point between the rolls,
when the side roll rises and forms the plate,
when the side rolls positions are inverted,
when activating the rolls rotation to move the plate
(risking to select the wrong sense of rotation)
when finished the forming of a circumference sector
rolling cones or profiles,
when opening the machine to remove a closed shell
or other unstable plate conditions.

These phases are extremely dangerous as the plate, if

fed too closely to the tangent point, could be un-
clamped and fall out of the machine.

SO IT’S ABSOLUTELY FORBIDDEN TO STAY

BEHIND OR UNDER THE PLATE AND
GENERALLY ON THE SIDE OF THE MACHINE
WHILE ROLLING, DUE TO THE HIGH RISK OF
THE PLATE FALLING. NOBODY MUST STAY
IN ZONES “B” AND “C” DURING THE ENTIRE
ROLLING CYCLE. ONLY THE OPERATOR
CAN REMAIN IN ZONE “A”.

It’s moreover suggested to keep the plate slung to avoid

unwanted movements. Should the machine be equipped
with the side support, use it to hold the plate.

It is also suggested to use a feed table and protect the

area subject to rolling operations, forbidding access to
the personnel.

3.3 CONTROL DEVICES

3.3.1. The controls, mainly joysticks, are placed on the
console, well visible and identified by simple and error
free symbols.
The operating sense is relative to the desired
movement: e.g. moving the joystick down to lower a
roll and, vice versa, up to raise it.

3.3.2. The console is mounted outside of the machine

(3.1.3-A), in a safe position, not subject to the works
being performed, but ideal to visibly check the rolling

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 Operation Manual
procedure.

3.3.3. For safety reasons, all movements require the

voluntary operator’s action.

WARNING: the controls are of “presence” type,

(3.3.3-A): if they are not kept activated, they return
to their stop position. In case of danger, leave the
joystick to block instantly the movement.
3.4 SAFETY DEVICES
3.4.1. The previous paragraph stated as the first safety
measure, the simple release of the joystick to stop the
movement. A second safety device is the emergency
“STOP” push button placed on the console.
If pushed, it immediately stops all movements.
To restart the machine reset the red Stop push button
(turning it clockwise or lifting it up) and on manual
machines.

3.4.2. EVENTUAL FIXED TILTING SUPPORT

PROTECTION DEVICE

In case of machine equipped with a feed table,

conveyor, ejector, side support or any other accessory
limiting the access at the sides of the machine, the
eventual cable emergency stop system and/or the
support tilting protection could not be installed since
they are not operable and therefore not useful for safety
purposes. The buyer should avoid the access of any
person to the dangerous areas around the machine by
setting, at his own responsibility, appropriate gates,
barriers and other efficient protecting systems,
according to the rules and standards in force. The
manufacturer is available, upon request, to take care of
this matter. If the request is not done in writing and in
a
timely fashion by the buyer, the manufacturer will be
fully relieved by the latter from any present and future
responsibility as regards the system safety.

3.4.3 In case of pit, platforms, and each time these

safety devices cannot be perfectly efficient for any
reason, it is the responsibility of the buyer to modify
their position to make them perfectly efficient and
effective. This is absolutely required for the safety of
the personnel.
The pits or the platform MUST be protected by covers
making all the area perfectly safe. The operators and
any person that could move near the machine must be

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 Operation Manual
totally safe and protected by any risk of fall-down by
appropriate gates, barriers and any other device that can
make all the area totally safe and reliable for the staff.

3.4.4. As soon as the machine and equipment are

delivered to the site, the buyer’s first priority is to test
all the safety devices and check their perfect efficiency
and effectiveness.
Every 20 working hours or every week, but
immediately in case inefficiency is suspected, the
buyer must perform an extremely accurate check and
test of all the eventual emergency devices installed on
the machine. The whole machine must always be kept
perfectly efficient and safety rules must be followed
daily by all the personnel involved in the use or
however in the machine’s area.

3.4.5. It is the exclusive and complete responsibility of

the buyer to always keep informed and updated on
safety norms, all the personnel involved with the use or
however operating in the area of the machine. The
Manufacturer is available, if requested, to train the
buyer’s personnel. If not called to do such training in a
timely fashion, he will be relieved by the buyer from
any responsibility.
At any time, as soon as the lack of efficiency on any
emergency device is suspected, the buyer MUST
STOP IMMEDIATELY the machine at his own and
full responsibility and reset the perfect effectiveness of
the safety of the entire machine.

3.4.6. Hydraulic powered and built with silent

components, the machines are low noise, and in many
cases, they don’t need further applications to remain
within the standards. But unfortunately, in many cases,
the noise emission is not related only to the machine
itself, but it depends also by its operating system, its
fixing at the ground, the acoustics of the plant and the
global environment. It is the responsibility of the buyer
to keep the noise emission around the installation below
the standard level admitted by the laws, rules and
regulations.
Sometimes very simple acoustic barriers should be
sufficient; in other situations the use of acoustic
protections must be imposed to the personnel; in other
seldom instances it could be required to build efficient
and specific acoustic barriers or also to soundproof the
machine itself inside a cabin.

FOR ALL THE REGULATIONS OF THE

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PRESENT CHAPTER 3 “SAFETY”, THE BUYER,
IF NOT SUFFICIENTLY INFORMED OR
EXPERT, AND IN ANY CASE OF NEED, CAN
CONSULT SPECIALIZED COMPANIES.

THE MANUFACTURER IS AVAILABLE, UPON

REQUEST, TO TAKE CARE OF THIS MATTER.
IF THE REQUEST IS NOT DONE IN WRITING
AND IN A TIMELY FASHION, HE WILL BE
FULLY RELIEVED BY THE BUYER FROM ANY
RESPONSIBILITY REGARDING THE SAFETY
OF THE MACHINE.

NO CLAIMS SHOULD BE ACCEPTED LATER

ON REGARDING THE EFFICIENCY OF THE
SAFETY AND EMERGENCY DEVICES.

3.5 MACHINE PERSONNEL

The personnel who will work on the machine must be

trained for the job to do on the machine and follow
carefully what written on the user manual.
Never do any maintenance if not foreseen in the user
manual, prior to have contacted the nearest Promau
service centre.
All maintenance interventions, ordinary or
extraordinary,
can be done ONLY WITH THE MACHINE
SWITCHED OFF 3.5-A (with the main switch in
“OFF” position).

The machine personnel’s clothing must confirm with

the existing safety regulations: however avoid
anything that could be fed by the moving rolls, as i.e.
belts, overall parts, long hair, etc…

Pay always the maximum attention to the rolls feed

danger and eventual crashing risks due to rolls, supports
or guides movements. (3.5-B, 3.5-C, 3.5-D).

The machine personnel will have to signal with physical

barriers and signs any intervention being done on the
machine. At the end of the intervention, the machine
will
have to be working properly, complete of each part.

It’s forbidden to anybody to follow the profile or plate

feeding with the hands (3.5-B)

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 Operation Manual
3.5.1. THE OPERATOR is the person who will use the
machine so he must know how to use the rolls
movements to obtain the desired shell. He will have to
use all the individual protection safety devices (DPI) as
foreseen by existing regulations as: overall, work shoes,
glasses and gloves.

He will keep the machine perfectly clean and efficient.

Before to start up the must he will make sure that
NOBODY will stay inside the forbidden area, included
the movable console (if existing) and that is possible to
control the machine in all of its functions.

The machine can be stopped at any moment, by pressing

the red EMERGENCY push button (placed on the
console) that should be operated instantly in
case of danger conditions for people or things due to
working errors or machine failure. (Noise, oil leakage,
etc)

3.5.2. THE MAINTENANCE operator is the person

who is in charge of the mechanical and hydraulic
maintenance of the machine.

3.5.3. THE ELECTRIC MAINTENANCE

operator
is the person who is in charge of the electrical
maintenance of the machine.

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 Operation Manual

4.MAINTENANCE INSTRUCTIONS
4.1 HYDRAULIC DEVICE
4.1.1. Check every 20 hours (or each week) the
hydraulic oil level 84.1.1-L) and fill (filtering in
advance) if necessary, always with the same type of oil.

WARNING: Never work with an oil level lower than

the minimum, to avoid serious damage to the hydraulic
device.

4.1.2. After the first 200 working hours (or 3 months),

replace the filter cartridge on the return oil line (4.1.1-
F). Later on, every 400 working hours, check the state
of the filter. If necessary, replace it.

WARNING: The cleaning of the hydraulic oil is

essential for long components life.

4.1.3. Replace completely the oil and the cartridge filter

(4.1.3) every 2000 working hours and, in any case,
every year.

The yearly replacement of the oil if very important for

the proper functioning of the hydraulic system.

At each oil replacement replace also the exhaust filter

(4.1.1-F)

WARNING: Use only original filter replacement

parts, ordering them from PROMAU.
THE USE OF NON-ORIGINAL FILTERS (AS
FOR ALL THE SPARE PARTS) COULD VOID
THE WARRANTY.

4.2 PLANETARY REDUCERS

4.2.1. Check every 40 hours (or every month), the lock

of the bolts “A” (4.2.1) that keep anchored the
planetary reducers to the roller joint.

4.2.2. Each 200 working hours (or every year), replace

completely (filtering it in advance) the oil inside the
reducers). This can be done as follows (4.2.1):
- unscrew the lower nut “S”;

20
 Operation Manual
- unload the oil;
- close the nut
- fill the oil up until it spills from the level cap “D”.
close the nut; close the nut; close the

4.3 HYDRAULIC COMPONENTS

4.3.1. Check each 200 working hours (or each month),

but IMMEDIATELY in case of oil level drop or oil
traces on the floor, all hydraulic devices (valves,
joints, hoses, gauges etc). Verify eventual leakages and
tighten everything that could be loosen.

4.3.2. It’s absolutely forbidden to intervene on the

adjustment of the hydraulic valves (4.3.2). These are
indeed sealed to avoid damages and calibrated by
PROMAU QUALITY CONTROL during testing prior
to shipping.

WARNING: in case of damage to the seal, immediately

stop the machine, until further authorization by the
manufacturer to use it again, under warranty.
PROMAU must be informed in writing. The loss of the
seal, if not declared as stated above, can null the
warranty, relieving PROMAU from any responsibility
for damages to the machine.

NON-ORIGINAL COMPONENTS (AS FOR ALL

THE SPARE PARTS) WILL IMMEDIATELY
VOID THE WARRANTY.

4.4 MACHINE CLEANING

Usually the plates to be rolled are dirty, often rusty and

release mill scale while rolled. The plate roll has been
designed and manufactured to work in such hard
conditions, but however, it needs care, constant and
accurate maintenance and cleaning in the following
points:

4.4.1. Coupling between the upper roll bushing and the

end yoke (4.4.1-A and B). It must always be perfectly
cleaned from chips, mill scale and generally from any

21
 Operation Manual
dirt as they could interfere with the end yoke opening
and closing, as well as the end yoke’s guide (4.4.1-C).
Protect by using Molykote “D-321R Spray grease” or
similar product.

4.4.2 Eventual slag bucket: clean each 200 working

hours (or even before if using dirty plates).
Use extreme care during this operation to avoid
hydraulic or electric damages; use industrials vacuum
cleaners.

4.4.3 Lower roll’s sliding guides (4.4.1-D): during the

pinching phase, the lower roll raises and lowers
between the two sliding guides on auto-lubricating
pads. The pads do not need any lubrication, but they
must be kept perfectly cleaned to avoid seizing. They
have to be checked and be perfectly cleaned every 20
working hours by sucking, and thus removing, every
impurity.

4.4.4. If the machine isn’t used for long time, grease the
rolls to prevent eventual rust or oxidation.

It is suggested to grease the surface between the

parallelism regulation screw and the eccentric bar,
approx. each 200 working hours or after 3 months.

5. GENERAL USE INSTRUCTIONS

5.1 INTRODUCTION
IMPORTANT: It must be always considered that plate
quality is very important in order to obtain a good
rolling result, especially on machines for high
precision
works, like NC equipped machines or pre-bending
machines. Certified sheets with distension treatment
(stress released) are ideal for this type of plastic
forming machine.
The sheet’s characteristics the greatly influence the
forming result are indeed: resistance homogeneity,
thickness, planarity, lamination fibres
direction
(parallel or transversal to the rollers), the residual
stressing, squaring.
Using sheets with different mechanical, physical or
chemical features determines the differences in rolling
diameters, thus making tolerances, results and rolled
part quality poor. The more the plates are of high

22
 Operation Manual
quality and consistent among them, the more the
rolling
results will be similar in diameter and of improved
quality.
The most frequent and clearest evidence of this
situation is well known to the operators every time
they
roll on their machine an entire pack of sheet supposed
to have the same features.
More often it happens that, even if moving the rolling
cylinders always at the same position, the final rolling
diameter will result different almost on every shell.
This is the actual proof, directly verifiable by the
operators, that the difference that makes the final
diameter different, resides in the sheet itself, having
faithfully repeated the same positionings on the
machine for each following operation.
The sheets were therefore different among them in one
or more characterizing parameters influencing the
diameter, whether noticeable or however physically
verifiable (thickness, resistance, fibres cutting sense,
planarity) or unknown and difficult to verify (yield
point, elastic return, residual stresses, weight of the
sheet), but often mostly responsible for differences of
diameter.
The most evident demonstration of this is easily found
on Numerical Control machines. The repeated
positionings repeated by the high precision automatic
control devices assure a precise repetition of the
rollers
positioning.
But more often the final rolling diameters are different
because of the different features of the sheet.
Moreover it is hard to compensate these differences
using compensation devices installed on Numeric
Controls, since they are able to detect and compensate,
only some of the diameter influencing factors (like
thickness, tensile strength, weight), and very rarely
some others (resistance, fibres cutting sense, planarity,
elastic return, residual stresses).
But what makes actually difficult to compensate sheet
differences is that all the differences influencing the
diameter get summed.
A compensating device could correct one of these
factors but its action could be nullified by other
factors.

5.2 PLATE PREPARATION

5.2.1. An accurate sheet preparation improves the

23
 Operation Manual
rolling quality and preserves the rolls surface,
avoiding scratches.
Before being inserted among the rolls, the sheet
must be cleaned and prepared as follows:

- Remove every flash slag or residue produced by

cutting the sheet along the edges, especially if the
sheet has been cut by flame; any metallic residue
must be removed carefully because excessive
hardness could seriously damage the rolls’ surface.
This operation can be done with an abrasive wheel
and must make the edge perfectly smooth, like if
bevelled. (5.2.1-A).

- clean the entire sheet’s flat surface until it is

completely free of welding residues, rust and any
outrigger that could cause damage to the rollers
(5.2.1-B) or modify the rolling diameter, by
changing the sheet thickness (absolutely
unacceptable in case of NC application);

- if necessary proceed with complete sandblasting of

the sheet

5.2.2. Some suggestions to reduce working defects

and to improve rolling quality.

- The sheet must be completely flat. It must not be

waved, bent in any part of its surface, deformed in
any direction (5.2.1-C). This is required because
rolling is a deforming process and if the sheet’s
surface is (totally or partially) deformed, rolling can
result irregular or of poor quality.
- The sheet should be sustained during all rolling
phases (from introducing the sheet into the machine
up to the rolling of the final diameter) because the
weight of the sheet could modify the rolling
diameter. (5.2.2).

The above mentioned instructions become

imperative when using NC machines, because the
final result could be dramatically influenced by
these factors, getting absolutely useless the high
precision NC.
Since rolling results depend more on the sheet that
on the machine, for this reason the only
responsibility bore by the manufacturer when using
the NC is the accurate repeatability of the machine
positioning.

No responsibility can be bore by the

manufacturer for the consistency of diameters

24
 Operation Manual
rolled on the machine, as the diameters depend
mainly by the plate tolerances, rather than by the
machine itself.

5.3 WORKS MEASURES

5.3.1. PINCH PRESSURE REGULATION

It’s one of the most important phases of the whole

rolling process.
The pinching pressure, to guarantee a good rolling result
and
preserve the integrity of forming rolls, must be correctly
evaluated according to the following instructions.
To regulate the pinch pressure act on the appropriate
regulator: by rotating it clockwise, the pressure increases,
by
rotating counter clockwise the pressure decreases
(5.3.1).

5.3.2 NARROW PLATES

Position narrow plates always at the centre of rolls for a

better rolling result. Mantain a pinch pressure as
low as
possible, just enough to move the sheet; this will
avoid to
concentrate excessive efforts on a short section of the rolls
(5.3.2.1).

EXCESSIVE PRESSURE COULD PERMANENTLY

BEND THE ROLLS (5.3.2.2)

IMPORTANT: to reduce risk of damages when using

narrow plates, the side rolls pressure MUST NEVER
EXCEED the values indicated in the following chart

25
 Operation Manual
(when pinching, check carefully the pressure value
indicated by the gauge).

Maximum
Sheet length Pressure
Allowed
100% 100%
80% 85%
60% 75%
50% 70%
40% 65%
30% 60%
20% or less 55%

If exceeding these values, please ask for written

authorization by the manufacturer.

It’s strongly suggested to square the sheet on the long side

of
the sheet. Squaring on the short side against the side rolls
could not be accurate because of wrong cutting
operations.
5.3.3 WARNING

Before starting a work, make sure of the complete

closing of
end yoke, by using the appropriate lever on the control
panel.

5.3.4 COMPULSORY REQUIREMENTS

One of the major risks that can occur during the PRE-
BENDING phase, is to bring the edge of the plate beyond
the
tangent point of the pinch between the pinching rolls
(5.3.4.1).
This can easily generate very strong cavitations on the
hydraulic motors of the machine. These very strong
cavitations occur when the motor, even for only a few
seconds, instead of “pushing” the rolls to rotate, is instead
“trailed”, “pulled” by the load, so it doesn’t work as a
motor
but as a pump.
For this reason, since the motor is not able to suck enough
oil
for the required revolution speed, the pistons inside the
motor
risk to break the axial supports that keep them fixed on the
motor’s shaft.

26
 Operation Manual
This generates a violent expulsion of the plate, outside the
pinch point, through the rolls, so that the load goes
from
maximum to zero, giving back all the potential energy
of
elasticity accumulated from the mechanical
components and
could make the motor turn backwards, therefore work
as a
pump.

On the machine, valves have been mounted so that in

normal
working conditions check the motor, avoiding
cavitations, but
in extreme conditions as when the plate is expulsed
violently
from the pinch between the rolls, cannot completely
protect
the motor (when the plate is brought beyond the
tangent
point).

Also the re-rolling phase could be at risk of cavitations

that
could destroy the hydraulic motor. During calibration,
it is
recommended to reduce the thickness down to about
75%.

NOTES FOR THE OPERATOR:

WARNING:

1- Avoid absolutely to bring the edge of the plate

beyond the tangent point of the lower roller, keeping a
minimum part of the plate always pinched, thus having a
safety margin, not to risk expulsion.

2- When re-rolling already welded plates without constant

radii, before starting the work, check that the thickness
does not exceed 75% of the machine’s pre-bending
capacity.
One of the most dangerous conditions, that can
cause
damages to the machine, it’s inserting an over

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 Operation Manual
thickness
between the sheet and the two pinching rolls
(5.3.4.2).
Should rotating start under this condition,
permanent
damages to the roller or to the entire machine
could occur
(up to make necessary roll replacement).
Another “high risk” situation occurs when
completely
lowering (till the mechanical stop) the central
roller, and
introducing a plate or profile between the rolls
trying,
consequently, to bend it moving another roller of
the
machine or introducing an over thickness between
the
plate and roller and starting the rotation (5.3.4.3).
This
extreme condition could cause serious damages to
the
rolls as well as to other machine components.

5.3.5 ENVIRONMENT

The machine must be installed in an appropriate working

environment, the area surrounding the machine must
always
be kept clean, free from obstacles and well lit. The machine
should not get in contact with water, oil and other liquids.
The machine should not be stored or work in dirty and
dusty
rooms. Too high or too low environment temperatures, as
well as too much humidity could influence the proper use
of
the machine. Soil, smoke, vapours could enter inside
machine
devices, causing damages, impeding the proper functioning
and causing extreme wear of electric, electronic and
hydraulic components.
Waste disposal is the responsibility of the user, according
to
local regulations.
Oils recovering and disposal must be done with the use of
suction devices foreseen by the user.

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 Operation Manual
5.4 ROLLS CAMBERING

The rolls are supplied with cambering in order to

partially compensate the deflexion due to the load during
rolling.

The upper and lower rolls have a central cylindrical

segment (whose length can change) and the remaining side
parts shaped in two, four (or more) conical segments, in
conformity with machine sizes and rolling applications
(Fig 5.4.1).

This operation is performed to avoid one of the most

common defects on the plates after rolling: the BARREL
defects of the edges (5.4.2).

A - The barrel defect makes the shell tightly closed at the

ends and lightly opened in centre (5.4.2). This occurs
because of the rolls deflexion, that makes the plate free
and not pinched in the centre. This defect worsens when
increasing the thickness (thick plates); to reduce it, the
pinching pressure must be reduced (5.4.3). The rolls
cambering could, on the other side, generate the opposite
defect: the “reel” defect.

B - The reel defect makes the shell tightly closed in the

centre and lightly opened at both ends (5.4.4). This occurs
because of the rolls cambering that make the plate free
and not pinched at the ends. This defect worsens by
reducing the thickness (thin plates); to reduce it, the
pinching pressure must be increased (5.4.5).

Cambering is designed for an average application

within
the machine capacity, between the “barrel” (on thick
plates) and “reel” (on thin plates). Being the
cambering
calculated for an average application, a thick plate
must be barrelled, as well as a thin one must be reeled,
while
rolling. It is however suggested to have an average
cambering, in order to obtain acceptable results on a
wider range of thicknesses.

It is however possible, on pre-bending machines, to

partially correct the defects due to the rolls cambering
with pinching pressure.

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 Operation Manual

6.MAIN APPLICATIONS
6.1 PRE-BENDING
The following procedure is based on the feeding of the
machine from the right side; in case of opposite feeding the
procedure must be inverted.

6.1.1. CLOSING IN ONE PASS.

PHASE 1 - Feeding and squaring of the plate
(6.1.1.1).

The two central rolls are “opened” (The lower “P” roll is in
its lower position). The right front roll “Y” is slightly
higher, in order to obtain a slightly tilted plane where to
feed the plate between the rolls.

The left rear roll “X” is at a height so that the plate can
touch the roll at approximately 25 mm below its
horizontal axis.

Feed the plate between the two central rolls pushing it

against the rear roll “X” , obtaining a perfect squaring.
(Should the plate be too narrow, don’t rely upon this
squaring against the rear roll, but check the square of the
plate on the longer side of the plate).

After squaring, lift the central roll up to pinch the plate

against the top roll, reaching the desired pinching pressure,
by means of the pressure regulator that you can find at front
of the machine on the right. (6.1.1.2):

- Lift the lower roll up to touch and press against

the top roll;

- keeping the lever pushed on the lift position, read

the
hydraulic pressure on the gauge;

- rotate the pressure regulator up to reach the desired

pressure (clockwise to increase it and
counter-clockwise to reduce it);

The plate pinching will be maintained for the whole rolling

process, to have an optimal control of the feeding of the
plate.
After pinching, check that the plate is still in the
squaring position.

30
 Operation Manual
Then go to the following step.

NOTE: The squaring is a very important phase: a

non-correct
squaring will give poor final results. The four rolls-machine
is the most suitable machine for the squaring of the plate.
Using the side roll as reference and keeping the two central
rolls pinched, the squaring will be maintained for the
whole rolling process.

PHASE 2 – Return to the tangent point (6.1.1.3)

After squaring, keep the front roll “Y” at

approximately the same height of the lower central roll
“P”, to hold the plate horizontally.

Feed the plate backwards to bring the plate to the

nearest tangent point, at which the two central “S” and
“P” rolls pinch the plate.

WARNING: This phase is very important for a good

pre-bending.

The further the plate will be to the tangent point, the

poorest the pre-bending and the long flat side will be.
Nevertheless, the nearest the plate will be to the
tangent point, the higher will be the risk of slipping or
escaping of the plate from the rolls.

FOR THIS REASON IT’S STRICTLY

FORBIDDEN TO
ANYONE TO STAND NEAR THE BENDING
MACHINE
DURING THE ROLLING PROCESS, FOR THE
HIGH RISK
OF SLIPPING AND FALLING OF THE PLATE.

Furthermore it is suggested to always hold the plate by

means of a
crane or to support it on a feed table or a side support, to
avoid
dangerous and not desired collapses.
It’s also suggested to protect the front area, to prevent the
access of
non-authorized personnel.

PHASE 3 – Pre-bending (6.1.1.4)

31
 Operation Manual

Lower completely the rear roll “X”, used for the squaring
and not
necessary in this phase.
Lift the front roll “Y” up to the rolling position, to obtain
the
desired diameter.
This position must be estimated by the operator or it can be
found
by trial.
Go immediately to the following rolling phase, to avoid
that the
plate, if tilted, slips from the machine and falls.

WARNING: This phase must be executed with

extreme care.

If lifting too much the “Y” roll:

- The plate would bend excessively, thus requiring

excessive torque during the following rolling
process;

- Even if having the necessary torque, the diameter could

be too close. (very difficult to correct)

WARNING -DANGER !!
IT’S FORBIDDEN TO ANYONE TO STAND AT THE
REAR
OR UNDER THE PLATE IN THIS PHASE.

IT COULD HAPPEN THAT DURING THE LIFTING

OF
THE SIDE ROLL, THE PLATE SLIPS OUT FROM
THE PINCHING POINT, BETWEEN THE TWO
CENTRAL
ROLLS.

This danger could be caused by a wrong manoeuvre of

the operator to feed the plate (verify carefully the
feeding direction by means of the arrows placed on the
front console).

Moreover it’s suggested to keep the plate lifted with

the crane (if a feed table is missing) to avoid unwanted
movements. Therefore follow the plate during the

32
 Operation Manual
feeding using the crane, allowing a good feeding of
the plate and avoiding to keep it blocked.

Should the machine have the side support, use it to

always keep the plate lifted.

The use of a feed table is strongly recommended to lift

the plate and to protect the front area preventing the
access to unauthorized personnel.

FASE 4 . Feeding (6.1.1.5).

Control the rolls rotation and feed the plate:

WARNING! Pay attention to the sense of rotation,
checking the rotation arrow on the front console.

If the rolls shouldn’t move, lower the front roll a bit

(the one used for the pre-bending), reducing the
requested torque and allowing the plate feeding.

The initial feeding must be short; the plate, tilted,

could be subject
to excessive stress and loads, increasing the barrel or
reel defects.
Usually the rotation is enabled until pre-bent edge
reaches half of
the distance between the axis of the central rolls “S”
and “P” and
the rear roll “X”.

Nonetheless, the bent sheet must be touched by the rear roll

“X” in order to go to the following phase.

PHASE 5 – Side roll change and rolling. (6.1.1.6).

Lower completely the front roll “Y” (until it reaches the

“0”
position.)
(Should a feed table be present, stop the lowering of the
front roll
“Y” at the height of the central roll “P”, keeping the
plate
horizontal, just above the table).

33
 Operation Manual

The plate, that now is tilted, will descend below the

horizontal axis. The plate end already “pre-bent” will
change position approaching the top roll.
Lift the side roll “X” up to the position that will give the
desired diameter to the shell. Obviously the right
position will be found by the operator, but it will be
always higher than the one of the “Y” roll.

WARNING: This phase must be executed with

extreme care.
If lifting too much the “X” roll:
- The plate would bend excessively, thus
requiring excessive torque during the following
rolling process;
- Even if having the necessary torque, the
diameter could be too close. (very difficult to
correct)

Having placed correctly the “X” roll, control the

rotation of the upper roll, to feed the plate and obtain
the correct diameter for the entire process (6.1.1.7)

PHASE 6 – Closing the shell (6.1.1.8).

WARNING: the approaching of the plate (near to

finish the shell) to the central rolls is a delicate
moment of the whole process, very important for the
quality of the second pre-bending. The further the
plate end will be from the tangent point, the poorest
the second
pre-bending and the long flat end will be.

Nevertheless, the nearest the plate end will be to the

tangent point, the higher will be the risk of slipping out
of the rolls.
Should the plate not be completely closed, therefore
“prisoner” around the upper roll, it could exit and fall
from the machine.

34
 Operation Manual

IT’S ABSOLUTELY FORBIDDEN TO ANYBODY

TO STAND NEAR THE MACHINE DURING
ROLLING FOR THE HIGH RISK OF PLATE
FALLING.
Moreover it’s suggested to keep the plate lifted using
the crane to avoid unwanted movements.
Should the machine have a vertical or side support,
use it to keep the plate lifted.

WARNING: In case of closed shells, another risk is

posed by the possible overlapping of the two edges of
the plate (6.1.1.9).

The first pre-bending (already rolled and swinging

from the top), due to the weight of the shell that
tightens the diameter, could overlap with the other, still
flat edge, and enter, overlapped, inside the two central
rolls.

AVOID IT CAREFULLY TO PREVENT

DAMAGES TO THE MACHINE, TO THE
ROLLS AND TO THE PLATE.

PHASE 7 – Welding of the closed shell (6.1.1.10).

WARNING: Turn off the machine from the main

switch, connect ONLY the plate to the ground;
DON’T connect welders directly to the machine to
avoid damages to the bearings and to other
components due to strong electric shocks
(6.1.1.10).

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 Operation Manual

In case of difficulty to weld along the whole length of

the plate, first tack-weld the two edges.

PHASE 8 – Machine opening (6.1.1.11).

After having rolled a cylindrical shell, it will be

necessary to “open” the machine to remove the shell.

Check that the joint of the shell is in the lower

position;

lower the two side rolls, to release the pressure

from the plate;

lower completely the central lower roll;

Hook the shell at the two ends;

should the machine have a block for conical

rolling,
remove it.

Open completely the end yoke using the lever on the

console.

Don’t lift the shell too much, but keep it lifted between
the upper roll and the two side rolls, that could be used
as
guides on which to feed it;

- After shell removal, close the end yoke.

WARNING: During shell removal, with the end yoke

opened, no extra load must be applied to the upper roll, other
than its own weight.
Should the machine be provided with the tilting upper roll,
(not
standard on all the machines) tilt it completely using its
relative command on the console, and stop it at its
higher position.

After the shell has been removed, bring the upper roll to its
horizontal position, by keeping this command
enabled for a few seconds, to lift the tilting cylinder.

At this point it will be possible to close the end yoke.

WARNING: On machines with the tilting upper roll, a

safety
device prevents erroneous operations.

36
 Operation Manual

The electric by-pass prevents:

- To tilt the upper roll with the end yoke in the
closed
position.
- To close the end yoke if the tilting cylinder
isn’t completely
lifted from the upper roll.
There are two ways to round a plate into a rolling
machine:
they are called Rolling and Prebending.

6.1-A ROLLING PROCESS

The “Rolling” process uses both side rolls of the
machine,pushing against the plate, bending it around
the top roll.
This condition has the benefit to add the power of both
side rolls at the same time, at the same geometrical
position.
To get this condition, the plate must be positioned
above both side rolls, and pinching with the lower roll at
one max pressure of 30/40 bar (6.1-A.1).

With this procedure, however, a flat edge remains straight,

long almost the distance between the top and the side roll
axis (6.1-A.1).

This flat edge remains straight also at the other end of the
plate. This could be a problem for the geometry of the
cylinder (6.1-A.2).

There are however some cases when the two long flat
edges
remained straight could not be a major problem, or could
however be accepted on the rolled cylinder:

1) if a long flat edge should be required by the product

geometry (buckets for excavators, U or oblong shapes,
square tanks, and any eventual other part where a long
flat edge should be required) 6.1-A.3.

2) if a long flat does not disturb the geometry if the

diameter of the cylinder should be very large.

When, instead, a more accurate roundness is required,

37
 Operation Manual

the
long flat ends could be corrected as follows:

(Prior to roll on the rolling machine)

a) to previously round the two edges on a press-brake

by further bumping bending (6.1-A.4)

(after having rolled the cylinder)

b) cutting out the two long flats, and closing tighter

the
remained all round section of plate (6.1-A.5)

c) over-bending the ends at an “apple” shape and re-

rolling after welding (6.1-A.6)

In machines with “Re-Rolling” lever, to do the

re-rolling of
the shell, drop down the lower central roll in its lowest
position (6.1-A.6). Put the lever on “Re-Rolling”
position,
in this way all the feed power will be on the top roll
(6.1-A.7). For the full process see cap 6.2.3.

6.2 ROLLING DEFECTS

First of all the rolling defects, or more precisely, the

non
compliance with the rolling tolerances (especially if very
tight), are usually due to the operator experience, to the
material and, very rarely, to the machine. The
following is
the list of the most common rolling defects.

6.2.1 BARREL OR REEL DEFECTS

These are the most common defects as regards the

shells.
They are very well known to the operators, because
common to all the bending machines, depending on
the physical roll deflexion.

Experience suggests that both these defects occur

mainly
at the initial plate segment and less on the whole

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circumference. At 100-150 mm. (4"-6") from the edge the
shell is usually quite straight. Also, these defects are more
evident on the leading edge than on the final edge.
CORRECTION
The operators are aware about different correction
procedures in order to limit such kind of defects. The
following is a list of the most common:

A - SHORT DRIVING

Keep the first pre-bending as short as possible. The more

the edge will be driven in this phase, the more the
defect
will dramatically increase.
Pre-bend a section of plate corresponding to half the
distance between the lower central roll and the roll
opposite to one for pre-bending (sometimes even less)
(6.2.1.1)
Never roll a long section of plate during this initial
phase of pre-bending. This is unnecessary and can
only
worsen the defect.

B - PINCHING PRESSURE

“BARREL” DEFECT
The barrel defect could be reduced by keeping the
pinching pressure between the two central pinching
rolls
as low as possible by means of a proper valve (5.4.3),
before the last sliding feed, to obtain the required
diameter
in multi-pass feed process or on the following plates
of the same type: this manoeuvre will make a longer
flat edge but will improve the barrel defect.
Keep the pinching pressure as low as possible by
means of a proper valve. (6.2.1.2)

If not sufficient, after having placed the plate at the

tangent point with the pinching pressure at the
minimum, drop slightly the lower central roll to
further reduce the pressure.

“REEL” DEFECT
The reel defect can be reduced by increasing the
pinching pressure (5.4.5) between the two central
rolls, before the last sliding feed to obtain the final
diameter, or on the following plate of the same type.
Being the reel defect more frequent on thin plates, pay

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 Operation Manual
attention to the risk of lamination and, eventually
reduce the pinching pressure if needed.

WARNING: To change the pinching pressure, the

weight of the plate must be shifted on the roll.

Therefore balance the weight, putting it in the central

position and lower the side rolls so that that it does not
weight on the lower central roll.

Make sure that the plate doesn’t move out of control in

this phase in which it will not be blocked by the
pinching between the two central rolls.

Having to increase the pinching pressure (to reduce

the
reel defect), raise the lower central roll and, while it’s
pushing the plate against the upper roll, check the
pressure on the pressure gauge, increasing it by
rotating the regulation valve clockwise.

To reduce the pressure, in order to reduce the barrel

defect, turn the valve counter clockwise, reducing the
pre-load pressure before raising the lower roll, then
raise the roll that, pinching the plate will allow to read
the actual pressure. If too low, increase it by rotating
the valve clockwise; if too high repeat the above
procedure dropping the lower central roll.

C – ROLLING BEFORE PRE-BENDING

Change the usual and quicker rolling procedure,
therefore
roll the central plate section first, and then form the
two
edges.
This slows a bit the execution timing but gives 2
advantages:
- avoiding to start from pre-bending (reducing the
defects);
- the barrel or reel defects are reduced because the
already
rolled central plate section offers more rigidity and
resistance to the whole shell (the two ends as well).

6.2.2 CONICAL DEFECT

It can sometimes occur that a shell is not cylindrical
but
lightly conical (6.2.2.1). The diameters of both ends are
different; tighter on one side and more open on the
other
side.

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 Operation Manual
This can be due to:
- A non perfect parallelism between the rolls (that
must
then to be correctly set);
- A harder or thicker plate on one of its sides.

CORRECTION:
The side rolls should be tilted (only one or eventually
both if necessary) raising them on the larger diameter
in order to tighten it slightly, till it is the same as the
tightest diamter (6.2.2.2). Being the side rolls
inclinable ONLY if they raise near the end yoke, if the
larger diameter is on the other side of the rolls (near
the motor box), the shell must be removed and
reintroduced after turning.

6.2.3 OUT OF ROUND (OVALIZATION)

It could occur that a shell is not rolled at a constant

radius, being instead ovalized (6.2.3.1).
CORRECTION

To uniform the radius and make the shell as round as

possible, the operators are aware about the
“Re-rolling”
or “Calibration” procedures.
The max machine re-rolling capacity is 75% of its
max thickness.

The shell should be removed by the machine and

totally
welded. Then the welding must be carefully cleaned by
removing, inside and outside, all the dangerous,
extremely hard and sharp parts, making them totally
smooth.

Then the closed, rolled and welded shell can be

reintroduced into the machine for the re-rolling.
Bring the tightest diameter of the shell at the lowest
position, just under the upper roll.

Keeping both side rolls at the same position, raise them

until they touch the shell.
NB: The lower central roll it is in its lowest position.
Then raise them more, for another short stroke,
sufficient to deform the shell, bending it a little more,
with a shape of a “pear” (6.2.3.2).

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 Operation Manual

Put the lever on the motor side of the machine on its

“RE-ROLLING” position (6.2.3.3), thus excluding the
rotation of the lower central roll (allowing to feed
the
shell ONLY with the upper roll).

Enable the rotation: the shell will start to rotate.

At each turn, slightly drop the side rolls, continuing to

rotate the shell, always in the same direction (6.2.3.4).

After a few side rolls are lowered, alternated with

complete rotations, the thrust of the rolls on the shell
will be completely nullified and its position will be the
one correspondent to the final right diameter.

WARNING: the re-rolling must be done using ONLY

the upper roll and both the side rolls. THE LOWER
CENTRAL ROLL MUST NOT BE USED (6.2.3.5)

6.2.4 LAMINATION

If a plate should be scratched or laminated, the

pinching
pressure must be reduced between the rolls, by means
of
the proper reducing pinching pressure valve (6.2.4) till
the problem disappears.

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7. ELECTRICAL CONTROL SYSTEM DESCRIPTION

7.1SECURITY EXPLAIN
7.1.1 Power supply
Machine input power supply Three-phase, three-380V 60 Hz AC, steady-state voltage is between 0.9 and
1.1 times the rated voltage, frequency of 0.99-1.01 times the rated frequency, the total input power is 22
kW.Machine total power introduce from the bottom of the power cabinet part (L1, L2, L3)
7.1.2Ground connection
The machine must have a good grounding connection device, before connecting the power line, the
protection ground must be linked. The machine total grounding connection is on the cooper medal of the
machine electrical cabinet and it must be security ground connection use separate wires. The various
moving parts of machine have to need crossover protection grounding wires, grounding resistance less
than 4Ω
7.1.3 Maintenance and repair
Regularly check makes sure each motor insulation resistance within allowable range.Regularly check the
action of all lights, solenoid valves, contactors, digital display.
7.1.4 Electrical installation and debugging
PLC maintain :When start the machine, check the BATT light on or not in CPU module, if the light on
please change the lithium battery in CPU within one week or the CPU internal program will lose. Power
is power instruction light, the light on when the PLC working power under right circumstances. CPU
light is CUP monitoring light, this light not on when the CPU normally working, RUN light is instruction
light to monitor the PLC under right circumstances. Maintenance must be by skilled person, Do not touch
the components with wet hands.
7.1.5 Electrical install and debug
According to the electrical external wiring diagram to connect the motor, solenoid valve, handle button
wires and ensure charged body ground connection reliable, adjust thermorelay to reasonable value. Under
the good circumstances to let the machine action.Checking motor direction , limit switch direction and
accuracy.
7.1.6 Labour protection
When the professional person maintain the machine must wear appliances for labour protection, like
insulation shoes , before touch the components, must use the universal meter check the residual voltage in
case dangerous.
7.2 MACHINE OPERATION
7.2.1 Button operation

Emergency stop
When an emergency occurs,press it to stop the machine

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Stop/start machine
After connect the main power,turn it to right to start
machine.After finish work,press it to left to cut off the power

Oil pump start

Before start machine,press it to start oil pump

Oil pump stop

After finish bending,press it to stop oil pump

Drop end open

Press it to open the hydraulic drop end

Drop end close

Press it to close the hydraulic drop end

Manual/auto model
Press it to left,in manual model
Press it right,in automatic model

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 Operation Manual

Press to A,at same time push handle to up and

down to control A roll up and down.
Press to B,at same time push handle to up and
down to control B roll up and down.
Press to D,at same time push handle to up and
down to control bottom roll up and down

Press it,and push handle up and down,to control

the A roll fixed side up and down

Press it,and push handle up and down,to control

the A roll drop end side up and down

Press it,and push handle up and down,to control

the B roll fixed side up and down

Press it,and push handle up and down,to control

the B roll drop end side up and down

Press it,and push handle up and down,to control

the bottom roll fixed side up and down

Press it,and push handle up and down,to control

the bottom roll drop end side up and down

Turn it to control the top roll rotate in forward and backward.

Cooperative this Slow button to control the rotate speed.

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 Operation Manual
Indicator of power connect

Indicator of start machine

Indicator of oil pump start

Indicator of fault

7.2.2 Touch Screen Operation

Touch screen operation is combined with the console button and the operating handle. All operations of
the device are set on the touch screen and completed by the operating handle or the button action. Please
enter the password "2" before changing the parameters in the touch screen.

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 Operation Manual

7.2.2.1 start machine drawing (drawing 1)

drawing 1

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 Operation Manual

7.2.2.2 Manual Operation Screen（drawing 2）

a b

drawing 2

7.2.2.2.1 、In a area display the timely position data for each roller.【AF】 for A roller fixed side data.
【AO】for A roller drop end side data.Same as other rollers.
7.2.2.2.2 、In b area,it’s change between panel and touch screen.
7.2.2.2.3 、In c area,auxiliary tool.
7.2.2.2.4 、In d area ,the operation as below:

+ + ，press ,the light turn on,then push handle to

and to make the A roller fixed up and down separately.Same as other rolls.
7.2.2.2.5 、In e area,it’s for bending conical shape.Press it,there will show the incline drawing,press the

button

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 Operation Manual

Drawing 3 incline drawing

A. + ,push handle to A side and direction handle up and down to make A roller
drop end side up and down.

B. + ,push handle to B side and direction handle up and down,to make B

roller drop end side up and down.
That’s make the different height of two sides to bend conical shape.Turn off the button

,The two sides of A,B will elevation at the same time.

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 Operation Manual
7.2.2.3 Displacement Screen（drawing 4）

drawing 4

7.2.2.3.1 、In this drawing,set the MM/PPR and length ratio to make the distance data same as the
actual measure data of piston out length.Normally,the MM/PPR is” 0.03” ,the length ratio is” 1 “ .
7.2.2.3.2 、Length compensation is used to eliminate the error of machine structure during produce the
machine.Don’t need to change it.

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7.2.2.4 Parameter drawing（drawing 5）

Drawing 5

In this drawing,we have set the data already before despatch,need not to change any more.
7.2.2.4.1 、positive and negative time:0. 1S
7.2.2.4.2、jog time:0. 1S

7.2.2.4.3 、AB open loop error:1mm.This error is corresponding to ，

it’s the error of fixed side and drop end side of AB rolls when they are running. Turn off this button，
deviation will not work.Turn it on ,the rolls of fixed side and drop end side will keen balance
when the error within the set range.

7.2.2.4.4 、AB closed loop error:1mm，this error corresponding to ，it’s the

error
between fixed side and drop end side of A B rolls after they finish work.Turn it off,the deviation will not
work.Turn it on,Rolls of A, B will keep in balance in condition that error of the fixed side and drop end
side within the set range.

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 Operation Manual

7.2.2.4.5 、 AB closed loop time:0.5S,this is mean 0.5S later, the rolls of A,B will stop running
automatically after they stop work.
7.2.2.4.6 、tipping max. limit;the max.raise data of side rolls.
7.2.2.4.7 、side roller max. Distance:raise the side rolls to touch the top roller,record the data.It’s 999
before leave factory.
7.2.2.4.8 、creep speed distance:0.5mm
7.2.2.4.9 、D open loop error:
7.2.2.4.10 、D closed loop error:0.5mm
7.2.2.4.11 、D closed loop time:0.5s
7.2.2.4.12 、D roller Min. Limit:20mm.When open drop end,the position of D roller must lower than
20mm.
7.2.2.4.13 、U-D distance:the distance between top and bottom roller.
7.2.2.4.14 、D roller Max. Distance:the distance between top and bottom roller.This data must same as
item 13.
7.2.2.4.15 、U-D distance compensation:0mm.
7.2.2.4.16 、tumble time:the time for open drop end.
7.2.2.4.17 、man tumble 0/auto tumble1:after finish bending,open drop end by manual or by automatic.
7.2.2.4.18、press head time:it’s a extend time when balance tank back to original position and touch the
limit switch.
7.2.2.4.19 、down roller error：1mm，
7.2.2.4.20 、2rollers(0)/3rollers(1):

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7.2.2.5 Automatic drawing （drawing 6）

Drawing 6
7.2.2.5.1 、 clear “0” for A,B,D rolls.Fall down three rolls to the lowest position,Press ① area,it will

enter zero drawing.press zero for each roller.

7.2.2.5.2 、In ② area,input the plate thickness.

7.2.2.5.3 、 Turn the button to “auto”in control panel,press “start”begin to roll the plate.

Alignment for plate edge.Be sure the plate edge must in level.

when finish bending,press it to stop.

During bending plate,when need to pause,press it.If want to continue bend,press it again.In
“pause” station,you can operate machine by manual.
7.2.2.5.4 、③area display each oil tank up and down.
7.2.2.5.5 、④area is for limit switch.

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7.2.2.6 Circle （drawing 7）
Before bending circle,please ensure:
7.2.2.6.1. machine must be in synchronization;
7.2.2.6.2. Machine must be in clamp tighten.

Drawing 7

In this drawing,you need to input data for:T,R,Z compensation,L compensation,and B up (A) %.

T:The plate thickness;
R: Inner radius;
Z compensation:it’s used to compensate the side rollers height.Z compensation =A1-Z.The bigger
gap,the bigger data.
L compensation:it’s used to compensate the length of the plate to avoid the slippage of plate.This
data is negative number always,it’s from 10-30.B up (A) %:it a scope 60-80%.This data is for
prebending.
L=3.14*(2R+T),L,it’s the length of plate; R is inner radius;T is the thickness of the late ,all unit is
mm.
D: Bottom roller rising height;
Z: Side roller rising height;
Note:L,D,Z is calculated but not need to input.Other data we will set them Ex-work.

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7.2.2.7 Save data（drawing 8）

7.2.2.7.1 After input all data in circle drawing,press “Auto”

Drawing 8

7.2.2.7.2 Press ”Irregularity”

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7.2.2.7.3 In “ Irregularity” drawing,press “save”

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 Operation Manual

7.2.2.7.4 In save drawing, ①input the save group,such as “ 1”,or “2”....totally can save 100 groups
data. ②input the data of plate,such as 4(thickness)x200(radius),③save the data in PLC.

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 Operation Manual

7.2.2.7.5 After finish save,when need to read one group data to bend, ①press up and down arrow to
find the group you need,such as “3”②press”download” ；③press “auto” begin to bend the plate.

58