Epple Maschinen PW 30 User manual

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!

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 2 of 50
Table of contents
1SAFETY.............................................................................................................. 5
1.1 Safety notes (warning notes)............................................................................ 6
1.1.1 Classification of hazards........................................................................... 6
1.1.2 More, used pictograms.............................................................................. 7
1.2 Proper use.......................................................................................................... 7
1.3 Danger, which can emanate from profile roll................................................... 8
1.4 Qualification of personnel................................................................................. 9
1.4.1 Target group............................................................................................... 9
1.4.2 Authorised personnel................................................................................ 9
1.4.3 The operator must.....................................................................................10
1.4.4 The user must ...........................................................................................10
1.4.5 Special claims to the qualification...........................................................11
1.5 Operator position..............................................................................................11
1.6 Safety equipment..............................................................................................11
1.6.1 Main switch................................................................................................11
1.6.2 Emergency Stop control...........................................................................12
1.6.3 Prohibition, instruction 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
2TECHNICAL DATA .......................................................................................... 16
2.1 Electrical connection data................................................................................16
2.2 Machine data.....................................................................................................16
2.3 Machine dimensions.........................................................................................16
2.4 Environmental conditions................................................................................16
2.5 Emissions..........................................................................................................16
3ASSEMBLY...................................................................................................... 17
3.1 Delivery volume................................................................................................17
3.2 Transport...........................................................................................................17
3.3 Storage..............................................................................................................17
3.4 Positioning and assembly................................................................................18
3.4.1 Claims to installation location..................................................................18
3.4.2 Load rope stops........................................................................................18
3.4.3 Positioning plan........................................................................................18
3.4.4 Positioning ................................................................................................18

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 3 of 50
3.4.5 Anchor –free assembly............................................................................19
3.4.6 Anchored assembly..................................................................................19
3.5 First initiation....................................................................................................20
3.5.1 Cleaning.....................................................................................................20
3.5.2 Sight check/ manual function check........................................................20
3.5.3 Electrical connection................................................................................20
3.5.4 Function check..........................................................................................20
4HANDLING....................................................................................................... 21
4.1 Safety.................................................................................................................21
4.2 Materials and products.....................................................................................21
4.3 Electrical connection........................................................................................21
4.4 Control and indicator elements .......................................................................22
4.5 Activating the machine.....................................................................................22
4.6 Deactivating the machine.................................................................................22
4.7 Hand drive.........................................................................................................23
4.8 Activating and deactivating bending rolls ......................................................23
4.9 Adjust bending radius......................................................................................23
4.10 Tilt bending device........................................................................................24
4.11 Recommendations and assistance..............................................................24
4.12 Working notes...............................................................................................24
4.12.1 General notes............................................................................................24
5BENDING ......................................................................................................... 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
6ROLLER 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 straight external bow ........................................................................29
6.6 U-profile straight internal bow.........................................................................29
6.7 T-profile straight external bow.........................................................................30
6.8 T-profile straight internal bow .........................................................................30
6.9 Angle-profile straight external bow.................................................................30
6.10 Angle-profile straight internal bow ..............................................................30
7CHANGE ROLLER SETS ................................................................................ 31
7.1 Preparative work...............................................................................................31
7.2 Cycle: dismantle roller set ...............................................................................31
7.3 Cycle: Assemble new roller set .......................................................................31

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 4 of 50
8MAINTENANCE ............................................................................................... 32
8.1 Safety.................................................................................................................33
8.1.1 Preparation................................................................................................33
8.1.2 Recommissioning.....................................................................................33
8.2 Inspection and attendance...............................................................................34
8.2.1 Lubrication ................................................................................................34
8.2.2 Daily work..................................................................................................34
8.2.3 Weekly work..............................................................................................34
8.2.4 Monthly work.............................................................................................34
8.2.5 Semi –yearly work....................................................................................35
8.3 Maintenance......................................................................................................35
9FAILURES........................................................................................................ 36
10 EXPLODED DRAWING.................................................................................... 37
10.1 Schematic drawing 1.....................................................................................37
10.2 Schematic draiwng 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 electricity.......................................................................46
14 CIRCUIT DIAGRAM ......................................................................................... 47
14.1 Circuit diagram..............................................................................................47
15 APPENDIX........................................................................................................ 48
15.1 Copyright.......................................................................................................48
15.2 Product follow - up........................................................................................48
15.3 EG –declaration of conformity ....................................................................49
15.4 Acceptance certificate ..................................................................................50

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 5 of 50
1 Safety
Glossary of symbols
Symbol
account

Reference to another page

Calls on you to get in action

Gives additional indications

Forbidden

enumerations
This first part of the operating manual:
Explains the meaning and use of the warning references contained in the
operating manual
Highlights the dangers that might arise for you and others if these instructions are
not followed
Explains how to use the machine properly
Tells you how to avoid dangers
In addition to this operating manual 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 have to take some in –company actions before the use of the machine
to follow the country –specific instructions.
Always keep this document close to the machine.
Support / Information
If you are unable to solve a problem using this manual, please contact us for advice:
Epple Maschinen GmbH
Service und Support
Auf der Breite 2-14
D-73349 Wiesensteig

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 6 of 50
1.1 Safety notes (warning notes)
1.1.1 Classification of hazards
We classify the safety warnings into various levels. The table below
gives an overview of the classification on symbols (pictograms) and
warning labels for the specific danger and its (possible) consequences.
Symbol
Warning
alert
Definition/ Consequences
Danger!
Imminent danger that will 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 information
and notes. No dangerous or
harmful consequences for
personal or objects.
In case of specific dangers, we replace the pictogram by
General
danger
Injuries to hand
Dangerous,
electrical
tension

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 7 of 50
1.1.2 More, used pictograms
Engaging
forbidden
Draft mains
plug
Wear
protection
gloves
Wear protection
glasses
Wear ear
protection

Wear
protective
suit
Wear safety
shoes
Mind the
environment
Your contact
person
1.2 Proper use
Warning!
In the event of improper use, the machine
Will endanger employees,
Will endanger the machine and other material property of the operator,
may affect proper operation of the machine
The machine may not be in an explosive environment.
The use and positioning of the machine only is allowed in dry and well –aired
rooms.
The machine was built and construed fort he following 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 improper use. We would like
to point out that any modifications to the construction, or technical or
technological modifications that have not been authorised by Epple Maschinen
GmbH will also render the guarantee null and void.
It is also part of proper use that
The maximum values of the machine are complied with,
The operating manual is observed
Maintenance and inspection commands are followed
For an optimal efficiency, you have to observe the following:

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 8 of 50
The correct choice of the roller set, accordant to the material
The correct assembly of the roller set
The correct roller pressure (bending pressure)
Warning!
An improper use can lead to heaviest injuries.
The rebuilding or the change of the performance data is forbidden and endanger
personnel and machine.
1.3 Danger, which can emanate from profile roll
Construction and building of the machine equate to level of technique. The
machine was checked of operating safety.
However there exist risks and dangers by the use:
Improper use and non –observance of safety instructions can cause
extensive injuries like bruises, crops and fractures or separation of
members
Risk of injury by kickback of work parts
Risk of electric shock by electric units
Risk of stumbling by around lying work parts and work part rests
A cant of work parts can 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 be qualified and read plus
understand the operating manual.
By improper use of the machine may:
Danger for body and life exist
The machine and other property can be endangered
The safe function of the machine can be affected
It is very important that you disconnect the machine for cleaning and maintenance
work.
Warning!
The machine only can be used with functioning safety equipment. The machine
must be disconnected directly if you notice damaged or failure safety equipment.
All special units that are mounted from the operator have to include the
accordant safety units. You are not allowed to derogate or avoid the safety units
of machine. The responsibility therefore is the operators.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 9 of 50
1.4 Qualification of personnel
1.4.1 Target group
This manual is addressed to the operators, users and maintenance staff.
The warning notes therefore refer to both operation and maintenance of
the machine.
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 instructed operators
Trained and instructed experts of the retaile

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 10 of 50
1.4.3 The operator must
The operator is bound to instruct the personnel in regular intervals (at
least once a year) on
Monitoring all safety standards that apply to the notching
machine
Maintaining the operation
Obtaining accredited technical guide lines
Furthermore the operator is bound to:
Document training/ instructions
Require the staff to confirm participation in training/ instruction by
means of a signature
Control whether the personnel 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 personal protective wear (incl. skin protection)
Wear close work wear
Assure order and cleanness at the work place
Never work with broken machine parts
Announce failures directly to your superior
Red and understood the user manual
To be familiar with all safety regulations and equipment
Use the machine

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 11 of 50
1.4.5 Special claims to the qualification
For the work with electric units or operating materials more claims to the
qualification are efficient.
Only electronic experts are allowed to do work at electric units. If the
instruct and oversee you, you are allowed, too.
Before you accomplish work at electric units or operating material you
have to keep the following instructions in this order:
Disconnection
Assure against resetting
The unit must be de - energized
Please observe the effective regulations of the insurance association
and the accident prevention.
1.5 Operator position
The operator position is straight standing in front of the machine. Any other
position 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 abolished
You have checked the machine and fell confident that there is no danger
for personnel or property values
Warning!
If you remove the destined safety devices or abrogate them by bridging
you endanger yourself and other personnel working at the machine.
Consequences can be heavy injuries until death.
The machine includes the following safety equipment:
Main switch lockable
Emergency Stop control at machine and foot switch
1.6.1 Main switch
The main switch can be saved with an optional u –lock in the 0-position.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 12 of 50
1.6.2 Emergency Stop control
At the machine and the foot switch are an emergency Stop control with
that the machine can be stopped immediately. For the use of the
machine both emergency Stop controls have to be released.
1.6.3 Prohibition, instruction and warning signs
Observe additionally to the user manual the safety and warning notes at the
machine. Warning notes that only are to find in the user manual and not at the
machine have additionally absolute 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 your security check in an adequate way.
Checking in general
Safety equipment
Operation
OK
Safety notes
All safety notes are located and undamaged at
the machine
Function check of the safety elements
Element
Operation
OK
Emergency Stop
control
Stops the machine directly after use of the
emergency Stop control.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 13 of 50
1.8 Personal protective equipment for special work
Use for your work always the necessary personal protective.
Protect your face and your ears: Wear a safety helmet with a face guard for
every work, especially for any kind of work where your face and eyes are
exposed to hazards.
Use protective gloves when 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 work if the protective is complete.
CAUTION!
Contaminated, defiled protectives can release indispositions.
Clear them up after every use and at least once a week.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 14 of 50
1.9 Safety during the use of the machine
Warning!
Assure before use of the machine that no person is in danger or property values
are damaged.
Do not accomplish work at and with the machine which is safety alarming:
Assure that other people are not endangered by you
Observe the maximum bending capacity of the machine
Always deactivate the machine for control measurement at the work part
Wear adequate protective equipment
Never work at the machine if your concentration is limited (f. e. by
medicaments)
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 you are bound to inform
the operating personnel.
Announce and document changes which are safety relevant. Do not execute
changes without consultation with the manufacturer. Refresh the operation
manual only in consultation with the manufacturer. Only instruct the operation
personnel if all changes are approved.
Document the instruction in an adequate way.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 15 of 50
1.10.1 Breaking and assuring the machine
Deactivate the machine before the beginning of attendance and maintenance
work with the main switch. Assure the main switch with a u –lock and retain the
key. If applicable brew the mains plug.
Mark and assure the machine clearly against unauthorised resetting.
Warning!
Moves of machine parts and electric machine parts can hurt you and
others heavy. Act very careful if it is not necessary to unplug the
machine because of working. Inform personnel around you about your
cycle and the possible dangers.
1.10.2 Use of hoisting devices for attendance work
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. Assure that the load is fixed correctly. Never step
under lifted loads. Please observe 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 correct
function.
1.11 Accident report
Inform your superior directly about accidents or “nearly accidents”.
So –called „nearly accidents“ can have different causes and need a detailed
analysis.
1.12 Electricity
You are bound to let the electrical equipment of the machine check regularly.
We advise you at least a checking every 6 months. Deficiencies like damaged
cables or not fixed connections you have to correct always immediately
underneath observance of the safety measures. During work at live parts a
second person always has to be attendant who can switch –off the machine in
an emergency.
The machine must be out off gear immediately by failure in the electrical supply.
 You will find more information in chapter maintenance

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 16 of 50
2 Technical data
2.1 Electrical connection data
Connection
400V / 50Hz / AC3
Connection power
1,1 kW min.
Main motor
1,1 kW / 1500 U/min
2.2 Machine data
Type
PW 30
PW 30 HV
Head tiltable
no
yes
Axis diameter
30 mm
Roller diameter
118 –148 mm
Roller driving speed
20 U/min
Bending capacity rectangle full
50 x 15 mm
Bow diameter minimal
350 mm
Bending capacity rectangle
cavernous
50 x 30 x 3 mm
Bow diameter 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 possible that the acoustic emissions
cross the allowed extreme value (over 80 db(A)). Constancy of the emissions,
character of the working place and more machines influence the noise level at
the working place.
Therefore we advise to wear always ear protection.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 17 of 50
3 Assembly
The machine is delivered pre –mounted.
3.1 Delivery volume
After receipt of the delivery you have to check directly of shortfalls. Compare
the scope of delivery with the information at the packing slip.
Check whether the machine has damages in transit.
.
3.2 Transport
Warning!
If the lifting tool is not stable enough it can burst what may cause heavy or deadly
injuries. Please observe the following instructions 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 own safety. See that the load is
fixed correctly.
3.3 Storage
By an improper storage the machine or machine parts can be damaged.
Never store the machine under other environmental conditions than in the
operation manual denoted. The warranty claim declines by improper storage.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 18 of 50
3.4 Positioning and assembly
3.4.1 Claims to installation location
The machine may not be in an explosive area. The machine is therefore
not construed. The acceptable environmental conditions have to be
followed at the installation location. Organise the installation location
according to the safety regulations for the use of this machine. See that
the installation location is not limited for the use, attendance and
maintenance.
Guarantee a boundless and free amenability of the mains plug and all
operation unit of the machine.
3.4.2 Load rope stops
The machine 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 the
work place is ergonomic and follow the accident prevention regulations
for your business. The use, attendance and maintenance may be not
limited.
Bethink: A cramped work place recovers accident risks.
3.4.4 Positioning
Observe that the bottom/ ceiling are stable enough. If the rigidity is not
enough, it can come to oscillations between machine and bottom This can
lead to failures at the machine and adjoining units.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 19 of 50
3.4.5 Anchor –free assembly
Attention!
An anchor –free positioning is not allowed because of safety causes
and therefore it is forbidden!
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.

Stand 31.07.08, PW 30, PW 30 HV, Profile roll Page 20 of 50
3.5 First initiation
Warning!
At the first initiation through inexperienced personnel you endanger the
personnel and property values. We do not assume accountability for defects that
were caused by an incorrect use, f. e. by inexperienced personnel.
3.5.1 Cleaning
Clean up all parts that were supplied with anticorrosion agent for
storage and transport with petroleum
The use of dissolvers, diluents for cell lacquer or other cleanser
agents that may attack the lacquer are improper.
Observe therefore the information of the cleanser agent manufacturer
Oil all bare machine parts; use therefore 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 –assembled at the front side.
Check whether the circuit is accordant to the information of the
machine connection data.
3.5.4 Function check
Accomplish a safety check at the machine (view safety check at the
machine)
Let the machine run empty for one hour
Check the machine about bizarre sounds in both running directions
Check the temperature of the motor and the roller bearings
Let the machine run under load and check again about sound and
temperature