Hafco Metalmaster PR-132H User manual

Operating manual
Rolling Machine
PR-132H

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INDEX
INDEX PAGE 1
CONFIRMITY DECLARATION PAGE 2
GUARANTEE PAGE 3
INTRODUCTION PAGE 4
MACHINE DIMENSION PAGE 5
TECNICAL FEATURES PAGE6
MACHINE INFORMATION PAGE 7
SAFETY FACTOR PAGE 8-12
ENGAING PAGE 13-17
MACHINE USAGE PAGE 18-22
SPARE PART LIST PAGE 23-26
ELECTRICAL DIAGRAM PAGE 27
SIGNS PAGE 28-29

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The machine production in our factory is suitable to the
standards below.
European standards and instructions are listing at the table
below
Tel : Fax :
The machine production in our factory is suitable to the standards
below. European standards and instructions are listing at the table
below.
Machine name
ASYMMETRICAL THREE ROLLER BENDING
MACHINE
Machine Type
PR-132H
Production Year
and
Serial Number
.........../ ..........
EC- Instruction
EC-Standartds
International
Standards

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1.GUARANTEE
-The guarantee machine is 12 months
-This guarantee is valid for the materials and parts
wadable from fabrication faulty , should repair and
exchangeable only in this terms .
-This guarantee don't verify the replacement and repair
parts,carriage ,workmanship,travel journey expenses
-For carlees usage and damage ,this guarantee should be invalid
-At normaly conditions this guarantee shold be invalid for the erod
parts .
-This guarantee should be invalid,if the machine is using on the
other working operation and places
-The user manual for the cylinder machine ,should give you the
correct information and provide only general information

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2.INTRODUCTION
This manual includes placement operation, safety rules, maintenance, techinal
specification, spare parts list and electrical plan of Asymmetrical 3 Roller
Bending Machine,
There may be some difference between the manual and the machine because
of renwals and developments. Please contact the seller company during
assembling, operating and maintenance, this manual will help you and it should
always be handy
ATTENTION !
The machine should be operated by trained staff
Any modification on the machine without written conformation from is strictly
forbidden as such changes in the machine may cause damage or injuries.
Working area of the machine should be away from flammable and explosive
materials. It should be closed and should not be effected from air conditions.
Each time operator leaves off the machine, he should turn the main switch to
position "0" and should
Do not take off the safety covers from the machine.
The operator that will use this machine should confirm that he read the
instruction manual and understood everything.
Operator name and surname
Signature
Date
Employer

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Type
Serial No
OVERALL DIMENSIONS
Height ________________________mm
Lenght ________________________mm
Widht _________________________ mm
Weight Kg
ROLLS SIZES
Central Rolls mm
Side Rolls mm
BENDING SPEED
One Speed
POWER SUPPLY
Voltage
Total Power Installed
PERFORMANCES Y.P = -N/mm2 R = - N/mm2
Prebending Thickness_________________________________min Ф- ______ -
mm.
Prebending Thickness__________________________________ ____________ -
mm.
Bending Thickness -
mm.
PERFORMANCES LIMITS
The machine performance limits chance according to:
The kind of material (mechanic characteristics, hardness, yield point, etc.)
The diameter to obtain
The plate width in comparation with rolls working width

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PERFORMANCES LIMITS
The machine performance limits chance according to:
The kind of material (mechanic characteristics, hardness, yield point, etc.)
The diameter to obtain
The plate width in comparation with rolls working width
MACHINE INFORMATION
STANDARD EQUIPMENT AND OPTIONAL EXTRAS
Standard and special equipments of the machine are listed below. Standard equipments
already exits in all the machines. √symbols are out in the boxes next to special equipments
that are included in the machine you bought.
STANDARD EQUIPMENT
-The machine is fabricated of steel construction
-Rolls made of special steel
-Side roll bearing
-Upper and lower roll bushing
-Seperate control panel
-All functions of the machine are controlled from control panel
-Central rollers rotation is driven with reducer+electric motor
-Electrical precaution against overload.
-Electric installation. (Siemens, Telemecanique)
-To CE standars
OPTINAL EXTRAS
-- Side roll with motor □
-- Lower Roll with motor □
-- Hardened rolls □
-Cone bending device □
-Extended rolls □
-Section bending rollers □
-Digital display □
-Central lubrication system □
-Material pushing table □
-Foot pedal □
-Electric Voltage □

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SAFETY FACTORS
ASYMMETRICAL 3 Roller Bending Machine has upper and lower rolls rotating. Between those
rolls, operators hands or fingers may be trapped. Be careful no to allow any of your clothing or
hands between these rolls while they are rotating.
Do not do any maintenance when the machine is working.
-Be sure that the machine is off when you take off the back cover
-After closing the covers, control safety rope carefully
AT ANY DANGEROUS INSTANT : PRESS THE EMERGENCY
BUTTON OR STEP ON THE ROPE SURROUNDING THE
MACHINE
-In an emergency, the first thing to do is to press emergeny-stop button on the panel or to
step on the rope surrounding the machine
-Stop the machine before maintenance, repairing and cleaning -Never take off the safety
covers from the machine.

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POSSIBILITY OF DANGER ON THE MACHINE
On ASYMMETRICAL 3 RollerBending Machines, safety measures towards
danger are Taken. For example:
The electric installation has a metal closure.
Other dangerous part is the place where rolls rotate. By wrong and careless use,
dangerous situations may arise. During working, safety rope is mounted
around the machine towards accidents.
DAMAGE CAN HAPPEN
-User operator's fingers or hands
-User operator's clothes or other
subjects
-Deformed working material
-The third person when material
is bending
-Machine bending equipment....
All staff who run, install and maintain the machine are responsible to read the
warnings and apply the instruction manual. Do not attempt to bend hard
materials except form metal or aluminium sheet. You may give harm to either
the machine or yourself. To make modificition on the machine is forbidden
because of safety and productivity. Working maintenance and safety factors in
the instruction manual are supposed to be obeyed and applied.
FUNCTIONS OF THE MACHINE
Asymmetrical Bending Machines are produced to shape material and their
functions are shown below
This machine has the ability to bend closed and semi-closed pipes and conics.
Our machines are produced in different capacity and dimensions depending on
the thickness of the material bent Check sheet thickness on page 5 before
starting to bend material. Do not attempt to bend material that is larger than
indicated sheet thickness or quality.
To identify Asymmetrical Bending Machines, roll diameter, width of the bending
material and thickness of it are indicated.
For exampkle PR-132H 75 x 1300 x 2
PR-132H = Machine Type
75 = Roll diameter
1300 = Bending material width
2= Thickness of material (mm) that is 1,5 times larger than roll diameter
These values are valid for materials in St-37 quality.
Yield Pressure = 90 N/mm2
Straight Pressure = 130N/mm2

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APPROPRIATE USAGE OF THE MACHINE
All bending process should be done in front of the machine where control panel
takes place and only one person should operate Then placing material in to the
machine, another personnel sholud help, other bending process should be done
only by operator himself Therefore, operator take all safety precautions and he
should control in each step throughly Operator should take all safety
precautions and he should control in each step throughly
Around the machine, there should be a security area where max.bending
material can take place. And no one should be allowed to enter this area except
from the operator.
INAPPROPRIATE USAGE OF THE MACHINE
There should be no one in security area during bending process. During
maintenance electricity should be cut off.
No one should be allowed to step on the machine on any condition
SUITABLE OPERATOR
Young people under 16 is not permitted to run 3 Roller Bending Machine. The
operator who wil run this machine should confirm that he read instruction
manual and understood eveything.

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OPERATOR PROTECTION
In the situation that machine is working under normal conditions, operator
should not need any other measures. In working situation:
Because of the danger of dropping working material, workers should wear steel
type shoes and when handling hard and sharp working material they should
wear work gloves. For machine attention and maintenance expert staff should
have the right equipment.
-Allen key set
--Spanner Set
--Oiling gun
--Protective gloves
--Steel tip protective shoes
--Screwdriver set
SAFETY FACTORS WHEN SETTING UP THE MACHINE
PR-132H machine should be positioned on strong, hard and ground level.
(Check the ground plan)
The machine which have overturns can cause serious damage and accidents.
Material can not be bent properly in the machine that is not positioned correctly.
Besides,
damage may happen due to wrong positioning.
If the machine stands with stocks for a while before running, it should be
covered with an awning and should be protected from dust.
SAFETY PRECAUTINS
On page 10, asymmetrical 3 Roller Bending machine safety precautions are
shown. To check these factors also acheck list is added for the user (operator)
CONTROL THESE SAFETY PRECAUTIONS
-Control those factors for each working shift
-Please, check the safety elements once a week periodically
-After every service intervention and maintenance, control those safety
precautions.
THE CARE POINTS ON CONTROL

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-Check if the machine is in the correct
position
-Check if the machine functions
correctly.
-Check if the machine is mounted
safety.
Eliminate any problem or failure before running the machine. Stop the machine
immediately if you see any problem when the machine is running and contact
with the salesman
Do not take off the safety elements that instant of machine is running
or before
Safety Features
1- Protection plates
2- Switch on electric panel
3- Energy indicator on electric panel that shows there is electric power
4- Thermal indicator on electric panel.(indicates overload trip)
5- Emergency-stop button on the control panel
6- Key switch on the control panel
7- Displays on the control panel
8- Other buttons on the control panel
9- Warning labels
10-Soundness of the energy cable.
11-Connection cables of the control panel
12-Safety rope

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CHECK LIST OF SAFETY PRECAUTIONS
Fotocopy this check list in each control and use. Cofirm each point which functions
correctly by putting a √. And save it in case a failure arise.
CHECK LIST
CONTROL
CHECK LIST
DATE
□PROTECTION PLATES : They should be mounted and screwed.
□ELECTRIC MAIN ISOLATING SWITCH : It should be assembled
and it should be checked if it is working or not
□POWER LAMP : It should be assmbled and when there is power the
lamp sholud be checked if its on or off. Check it against bulb failure
□THERMAL LAMP : It should be assembled and when the thermal overload is
tripped it should turn on.
□EMERGENCY STOP BUTTON : It should be assembled on panel check if it
does its functions stops main motor.
□SELECTIVE KEY SWITCH (0-1) it should be assembled on panel. It should
function to switch on the display and control circuits
□DISPLAYS : Should be assambled and when there is power the display should
be on. Check function
□ALL OTHER PANEL FUNCTION BUTTONS : Should be assembled in and
function correctly
□WARNING LABEL : it should be fixed securely and it sholud be in a place
that can be seen easily
□POWER CABLE : it should be fixed securly to the machine it should not be
broken and or stripped. It should have safety protection against mechanical damage
□CONTROL PANEL CONNECTION CABLE : It should be assembled and the
flexible outer cover should be checked for damage.
□OIL CONTROL : Machine's oil level should be checked and manual
lucrication should be controlled. Tit is suggested that the machine is transported
with a covered waterproof folio no to be effected from air conditions.

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HANDLING AND LEVELING THE MACHINE
Always use high capacity quay and synthetic rope to lift the machine. Check lift
capacity of
ropes and compare them with the machine's weight on page 6
Pick up rolls and pin together as figure
İt is suggested that ropes are tightened first and then you lift the machine in
balance,
because
dominant weight is on the reducer side (not on the roll)
İt is required that you do not loose the ropes. Otherwise the machine may slide
and jolt.
UNPACKING
Asymmetrical Bending Machine are oiled and covered with waterproof folio to protect
machine from weather conditions during transport. During transport (in open vehicles)
use suitable tarpaulins or other covers additional to above films to protect from
weather
At unpacking, if you see any transport damage call the transporter or seller at once.
Dispose of the packaging safety and with regard to the environment use gloves when

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unpacking. Unpainted surfaces are protected with oil for transport. Clean this off with
"Kerosene" use gloves, dispose of waste wipers safely.
Cleaning of the machine, that is oiled with protective oil, is as follows,
Rolls and bright wrought surfaces are cleaned with thinner
-Painted surfaces are cleaned with a mixture of diesel oil and water
MACHINE GROUNDING MOUNTING PLAN
Machine mounting area should be arranged in accordance with mounting information
shown on page 16 and mounting plan on page 17. After controlling the machine's
position if balanced or not, it should be fixed. Decimal balance device should be used
to position the machine correctly and nuts should be checked.
MOUNTING INFORMATION
Before mounting the machine, pay attention to deimensions on page 5 and explanations below
1- Enough space should be left around the machine to reach every side of the machine for
maintenance.
2- On the front side of the machine, there should be space (Lx1,5) that is, 5 times larger than
sheet lenght to take off the material easily.
3- There should be enough space on both sides of the machine to bend material easily and
after this space, 1 meter walking area should be left

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ELECTRIC CONNECTION
Electric connection should be done by an experienced electrician. Before making
connection, the values should be checked on the label in electric box and electric
connection should be done according to these values
Push the energy cable in to the hole on the side of the machine. Connect energy cable
to the electric box through tube which is between electric box and hole Connecting
cable that is between the machine and control panel is screwed off seperately.
Attachthe multiple plug to socket

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MACHINE USAGE
To get high productivity, correct usage, correct maintenance and regular cleaning
should be done
Material should be prepared before bending due to its structure. For this:
1- Clean burrs which is on the edges of material cut with oxygen.
2- Clean all the spurs, rust,cinder. These may give harm to rolls, even if rolls are
hardened.
3- Clean both sides of the sheet.
4- Before starting to bend, check the sheet again. If there is a problem, clean
again.
Physical condition of the sheet effects quality of material bent. If the face of the
material is
dirty, the sheet may be grained.

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QUALITY OF MATERIAL
You know that semi-quality material, which is to bend, is delivered in different qualities.
Multiple bending materials can not give the same result because of the difference
between material quality.
The most important factor that effects bending quality:
1- Sheet quality
2- Flow limit
3- Elasticitiy limit
4- Material direction
5- If thickness is same on all surfaces of sheet or not; thickness homogeniety
These factors are so important that if one of them is changed, you can not get the
dimensions you bent.
For example, when you want to bend a material whose elasticity factor is high with the
same machine adjustment, diameter obtained will be different.
You might obtain different results, id you want to bend material in one step rather than
in two steps. Because, in two step procedure, flow limit might have changed after the
first step
These factor differences are faced (met) often even in the same material groups.
Therefore, you
Another bending fault occurs while bending big diameter material. While bending this
kind of material, it is bent correctly at the beginning. In the middle, it is sagged due to
its weight and spoils the radius. To prevent this, central and side guides should be
used.
PLACING MATERIAL
After doing all the safety factors shown on page 10, you can start to bend
materia lFirst step of bending process is to place material. To obtain a high
quality material bent, you should push and position correctly the material that
is squeezed in to rolls Initial steps of this process are:
1-Material should be placed into the rolls on any condition.
2-Material should be placed paralel to rolls axis.

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