NTM BG7 User manual

TABLE OF CONTENTS
i
CHAPTER 1……....
CHAPTER 2…........
CHAPTER 3……….
CHAPTER 4……….
CHAPTER 5……….
CHAPTER 6……….
CHAPTER 7……….
CHAPTER 8………
CHAPTER 9………
CHAPTER 10.…....
CHAPTER 11.…....
CHAPTER 12.…....
CHAPTER 13……..
APPENDIX A…….
APPENDIX B……..
SPECIFICATIONS ..........................................................................................1
PRECAUTIONS ..............................................................................................2
GENERAL MAINTENANCE.........................................................................3
Recommended Lubricants and Fluids......................................................4
ELECTRICAL CONTROLS AND OPERATION..........................................5
REEL STANDS, REELS AND EXPANDABLE ARBORS.........................11
HYDRAULIC SYSTEMS .............................................................................16
Maintenance...........................................................................................16
Hydraulic Fluid Troubleshooting...........................................................16
DRIVE SYSTEM...........................................................................................19
SHEAR ASSEMBLY.....................................................................................20
ENTRY GUIDE AND DRUM ASSEMBLY ................................................23
RUN OUT TABLES ......................................................................................24
POST-FACE KNIFE ROLLER .....................................................................25
TROUBLESHOOTING.................................................................................26
HOOK ASSEMBLY (OPTIONAL) ..............................................................29
Engaging or disengaging the hook.........................................................29
Move the bead roller..............................................................................29
PLC CONTROLLER .......................................................................................1
Home........................................................................................................2
Manual Operation ....................................................................................2
Automatic Operation................................................................................2
Job Entry..................................................................................................3
Programming Jobs ...................................................................................3
Clear Jobs.................................................................................................4
Auto Run..................................................................................................4
Automatic Operation................................................................................5
On the Fly Calibration .............................................................................5
Calibration................................................................................................5
Setup: .......................................................................................................6
Status/Diagnostics:...................................................................................7
Security:...................................................................................................8
Coil Tracking:..........................................................................................9
Colors.....................................................................................................10
Coil Length Calculator...........................................................................11
ELECTRICAL SCHEMATICS .......................................................................1

LIST OF FIGURES
ii
Figure 1: Controls...............................................................................................................................8
Figure 2: Main Control Cable.............................................................................................................9
Figure 3: Main Control Box Fuse.....................................................................................................10
Figure 4: QCPP E 1-6 Fuse Location ...............................................................................................10
Figure 5: Expandable Arbor Set-Up .................................................................................................12
Figure 6: Expandable Reel Assembly...............................................................................................14
Figure 7: Hydraulic System – Overview ..........................................................................................17
Figure 8: Hydraulic System – Details...............................................................................................18
Figure 9: Hydraulic Fluid Level .......................................................................................................18
Figure 10: Tightening the Chain.......................................................................................................19
Figure 11: Shear Height Adjustment ................................................................................................20
Figure 12: Shear Left-Right Adjustment and Removal....................................................................21
Figure 13: Entry Guide Adjustment..................................................................................................23
Figure 14: Entry Drum Adjustment..................................................................................................23
Figure 15: Run Out Table .................................................................................................................24
Figure 16: Post Face Knife Roller Adjustment.................................................................................25
Figure 17: Pressure Switch Adjustment............................................................................................26
Figure 18: Limit Switch Adjustment ................................................................................................28
Figure 19: Hook Assembly Adjustment ............................................................................................29
Figure 20: Bead Roller Adjustment...................................................................................................30
Figure 21: PLC Assembly...................................................................................................................1
Figure 22: Serial Number Plate...........................................................................................................1
Figure 23: Home Screen .....................................................................................................................2
Figure 24: Job Entry Screen................................................................................................................3
Figure 25: Specify Job to Run First....................................................................................................4
Figure 26: Auto-Run Screen...............................................................................................................4
Figure 27: Calibration Screen.............................................................................................................5
Figure 28: Calibration Screen.............................................................................................................6
Figure 29: Calibration Screen.............................................................................................................6
Figure 30: Setup Screen......................................................................................................................7
Figure 31: Status Screen .....................................................................................................................7
Figure 32: Security Screen..................................................................................................................8
Figure 33: Coils Password Access Screen..........................................................................................9
Figure 34: Coils Screen.......................................................................................................................9
Figure 35: Coil Indicator...................................................................................................................10
Figure 36: Coils Color Screen...........................................................................................................11
Figure 37: Length Calculator Screen................................................................................................11
Figure 38: Material and Thickness Screen........................................................................................12
Figure 39: Coil Dimensions..............................................................................................................12

CHAPTER 1
BG7 SPECIFICATIONS
1
SPECIFICATIONS
BG7 Dimensions: Length-14’ 6” (4.4m)
Width-4’ (1.7m)
Height-4’ 3” (1.3m) w/Over Head Rack
2’ 8” (.8m) w/o Over Head Rack
Weight-1800 lbs. (820kg)
SSQ on Trailer: Length-21’ (7.7m)
Width-7’ (2.1m)
Height-6’ 3” (1.9m) with reel
Weight-4560 lbs. (2069kg)
Speed: 60 ft./min. Approx. (18m/min.) Approx.
Drive: Hydraulically Driven Polyurethane Rollers
Shear: Hydraulically Powered, hardened tool steel dies and blades w/Panel
Recognition Proximity Sensor
Hydraulic Fluid: 15 Gallons - 32AW
Coil Width: 20” (500mm) Straight Back, Hook, Inside Flange
24” (600mm) Back Flange
Materials Formed: Painted Steel 26ga. to 22ga. (.4mm to .8mm)
Painted, Galvanized, Aluminized
Painted Aluminum .032” to .050” (.8mm to 1.3mm)
Copper 20 oz. to 24 oz. ¾ Hard
(.7mm to .8mm)
Controls: Standard: Manual Control Box w/Length Control
Limit Switch
Optional: Computer Batch and Length Control

CHAPTER 2
PRECAUTIONS
2
PRECAUTIONS
1. Make sure the operator of the machine has read and understands this manual in its
entirety before attempting to operate this equipment.
2. ALWAYS keep covers, guards and lids mounted to machine during operation
3. OBSERVE and OBEY all safety and warning signs affixed to the machine.
4. ALWAYS adhere to and follow all local and national safety codes concerning the loading
and un-loading of reeled coils.
5. USE ONLY properly rated devices for lifting reeled coils into or out of the reel stand
assembly.
6. DO NOT wear loose clothing, jewelry etc. that could become entangled in the moving
parts of the machine when operating.
7. STOP THE MACHINE and disconnect the power before attempting to make any
adjustments, perform any maintenance or changeover procedures.
8. AVOID storing the machine outdoors for long periods of time. Cover with a tarp but
provide good ventilation to prevent condensation and rust.
9. DO NOT USE SOLVENTS TO CLEAN DRIVE ROLLERS!
10. ALWAYS EMPTY MACHINE OF MATERIAL BEFORE TRANSPORT AND
STORAGE.

CHAPTER 3
GENERAL MAINTENANCE
3
GENERAL MAINTENANCE
1. Always keep covers on during operation and storage. The covers are for operator safety, but
also protect the internal components of the machine from the environment.
2. Avoid storage of the machine outdoors for long periods of time. Cover your machine with a tarp
to protect it but provide good ventilation to prevent condensation and rust.
3. Keep your machine clean. This will increase the life of the machine and make maintenance
easier. A clean machine will provide a clean product.
4. Before operating your machine, visually inspect for foreign objects, debris, or anything unusual.
If something doesn’t seem correct, inspect and remedy prior to operation.
5. Keep chains properly tensioned. This will add to the life of the chains and sprockets. The chains
should be just snug. An over-tightened chain is just as bad for the machine as a loose chain.
Idler sprockets are provided on each chain for this purpose.
6. Lubricate the chains a minimum of every 40 hours of operation. It is preferable to use a dry
motorcycle chain lube or equivalent.
7. Lubricate the drive gears a minimum of every 30 hours of operation. Use of an Open Gear
Spray Lubricant is recommended.
8. Keep Arbor Cradles lubricated with Clear Grease.
9. Lubricate Arbor Nut using a grease gun with EP Grease when threads begin to look dry.
10. Clean Forming Rollers as needed with a Scotch Brite Pad and a small amount of solvent.
11. Clean Drive Rollers with soap and water or mild solvent free spray cleaner. CAUTION: Do not
use harsh chemicals or solvents or damage will occur.
12. Lubricate both faces of the Shear Blades and Dies a minimum of once daily with Spray Lube.
More should be added as needed before the cut edges begin to deteriorate.

CHAPTER 3
GENERAL MAINTENANCE
4
Recommended Lubricants and Fluids
The following lubricants are available from New Tech Machinery.
Spray Lube for:
Shear Blades, Dies, Entry Guide, Bead Roller Carriage Shafts, Acme Shafts and Mitre Gears
Super Lube - Multi-Purpose Synthetic Aerosol Lubricant with Syncolon (PTFE)
NTM PN: LUBE-SPRAY - 11oz can
Clear Grease for:
Arbor Cradles
Synthetic Extreme Pressure, High Temperature Grease with Syncolon (PTFE)
NTM PN: LUBE-GEL - 400 gram container
EP Grease for:
Arbor Nuts and Pillow Blocks
Grease - Lubricants Type: Moly Ep Grease
NTM PN: LUBE-GREASE - 14 Ounce Container
Open Gear Spray Lubricant for:
Main Drive Gears
Open Gear and Wire Rope Lubricant
NTM PN: LUBE-GEAR - 11 oz. Aerosol Can
Hydraulic Fluid (32AW) for:
Hydraulic Tank
NTM PN: HYD-200-018 - 5 Gallons
(4 Required)

CHAPTER 4
ELECTRICAL CONTROLS AND OPERATION
5
ELECTRICAL CONTROLS AND OPERATION
POWER CORD REQUIREMENTS
For machines equipped with a QCPP-E it is very important to follow the power cord
requirement prescribed by the motor and electrical control manufacturers to maintain their
respective warranties. Make sure the cord you are using is marked properly. Do not assume
that because an extension cord looks heavy enough that it is the right gauge. Use of the
wrong gauge extension cord will void the warranty on motor and electrical controls.
GENERATOR USE FOR ELECTRIC MOTOR MACHINES
If a generator will be used to power the machine it must be large enough to handle the amp
draw requirements of the motor. Contact your local generator supplier for proper sizing and
refer to the specification plate on the electric motor. Use of an improperly sized generator
will cause a low voltage situation of the electric motor and controls which will void the
warranty.
MANUAL CONTROL PANEL OPERATION:
(Figure 1) A. FORWARD-REVERSE Switch
This selector switch controls the direction of movement of the material through the
machine. Select forward to feed material and run panel through the machine.
NOTE: For operator safety, your machine will not run continuously in reverse.
B. JOG-RUN Switch
This selector switch allows you to run the machine continuously, or jog material
through the machine. Select JOG to load coil into machine and to move material
through the machine in small increments until it clears the shear dies. Select run
after material has cleared the shear, and you are ready to run panel.
NOTE: The LENGTH CONTROL LIMIT SWITCH must be plugged in to the
Limit Switch Plug at the bottom of the Manual Control Box Assembly to run
continuously.
C. START FEED (Green button at Entry and Exit End)
This button is used to activate the drive system of the machine. (Jog only unless limit
switch is plugged in)
D. STOP FEED (Red button at Entry and Exit End)
This button acts as an emergency stop for the drive system when using the Length
Control Limit Switch. Pressing either the entry or exit button will stop the drive
system of the machine in case of an emergency.
E. SHEAR DOWN (Green button)
Pressing this button once will cycle the shear to the bottom of its stroke and return it
back to the top or home position. This is one shear cycle
F. SHEAR UP (Red button)
Pressing this button during the down cycle of the shear will immediately send it back
to the top or home position.
G. EMERGENCY STOP-POWER ON (Raised Red Mushroom button)

CHAPTER 4
ELECTRICAL CONTROLS AND OPERATION
6
Function #1 (Power On)
Pull this button OUT prior to starting the machine.
Function #2 (Emergency Stop-Power Off)
Once the machine is running, pushing this button in will stop all functions and
completely shut down the machine including the engine. If the shear is in the down
cycle it will freeze it in position. The shear will default back to the top or home
position once the engine or motor is re-started. This button is also used to shut the
machine down when not in use. Failure to push this button in prior to storage, even
overnight, could result in a dead battery on gas engine models.
H. MOTOR START (Green button)
You must pull the Emergency Stop-Power On button out before the Start
Button will function.
Press this button momentarily to start the Electric Motor machine.
Press and hold this button until the engine starts on a Gas Engine model.
MAIN CONTROL CABLE
(Figure 2) A. The main control cable is the communication cable for the Manual Control Panel
described above and the PLC Computer Batch and Length Control Computer
covered in Appendix B. This cable must be connected to one or the other in order
for the machine to operate.
B. The Main Control Cable exits thru the panel below and under the left corner of the
Manual Control Panel. There are three cables there and it is the larger diameter plug
of the three. It has a key and slot configuration that must be aligned before the
male/female connection can be made on the Manual Control Panel or Batch and
Length Control Computer. This prevents misalignment and damage to the pins.
Manual Control Panel Connection
Connect the Female end of the Main Control Cable to the panel mounted male
connection located at the bottom left corner of the Manual Control Panel. Make sure
that the key and slot are aligned and carefully start the threads on the connection and
turn clockwise until snug.
Batch and Length Control Computer Connection
Connect the Female end of the Main Control Cable to the panel mounted male
connection located in the bottom of the computer on the right side. Make sure that
the key and slot are aligned and carefully start the threads on the connection and turn
clockwise until snug.

CHAPTER 4
ELECTRICAL CONTROLS AND OPERATION
7
FUSES
(Figure 3)
All machines, gas or electric powered, have a 10-amp time delay fuse inside the Electrical
Control Panel Assembly. This fuse protects the electrical components. If the fuse is blown,
you will lose all functions of the machine except Motor Start. To replace this fuse: Loosen
all 4 cover screws and open the front panel of the Control Box. Locate the automotive style in-
line fuse near the bottom right hand corner. It is a spring loaded twist lock holder. Push
together and turn to open. Check the fuse with a continuity tester. If it is bad, replace with a
new fuse and re-connect spring loaded holder.
ELECTRIC MOTOR MACHINES
(Figure 4)
Electric motor machines have an additional 10-amp time delay fuse protecting the logic circuit
of the Contactor Box. This fuse holder is mounted in the side or top cover of the contactor box
located approximately mid machine on the right side. Access can be gained by removing the
center left side cover. This is a panel mounted, spring loaded fuse holder. To replace this
fuse: Push in on the cap and turn counterclockwise to release fuse. Check fuse with a
continuity tester. If the fuse is bad replace with a new fuse. To re-install, insert fuse into cap.
Install fuse and cap assembly into receptacle, push down and turn clockwise to lock in place.

CHAPTER 4
ELECTRICAL CONTROLS AND OPERATION
8
Figure 1: Controls

CHAPTER 4
ELECTRICAL CONTROLS AND OPERATION
9
Figure 2: Main Control Cable

CHAPTER 4
ELECTRICAL CONTROLS AND OPERATION
10
Figure 3: Main Control Box Fuse
Figure 4: QCPP E 1-6 Fuse Location

CHAPTER 5
REEL STANDS, REELS, AND EXPANABLE ARBORS
11
REEL STANDS, REELS AND EXPANDABLE ARBORS
EXPANDABLE ARBOR
(Figure 5)
The Expandable Arbor adjusts to accommodate coils with 16” to 20” inside diameters by expanding
into the ID of the coil.
THREADED NUT
The threaded nut should always be on the right side of the machine and the tail of the coil should
always be routed over the top and pointing toward the exit or shear end of the machine.
This threaded nut is used to increase or decrease the outside diameter of the arbor. Turning the nut
clockwise will increase the outside diameter of the arbor, and counter-clockwise rotation will
decrease the arbor size. There is a grease zerk in the collar of the threaded nut that should be
lubricated at least twice a year, or whenever grease in not visible on the threads of the shaft.
END COLLAR
The End Collar has two positions.
Position “A” is used for coils with inside diameters of 16”.
Position “B” is used for coils with inside diameters of 20”.
To adjust from one position to the other, remove 2 screws “C” until end collar is free to slide. Slide
it to the inside position for 20” ID or outside position for 16” ID coil. Align it to the respective
threaded holes in the reel shaft. Re-insert and tighten "C" bolts to lock the end collar to the shaft.
LOADING EXPANDABLE ARBORS WITH COIL
1. Using the Threaded Nut, collapse the arbor small enough to fit into the inside diameter of
the coil.
2. Slide the Expandable Arbor into the center of the coil making sure the threaded nut is on the
right and the tail of the coil is over the top and pointed toward the entry end of the machine.
3. Turn the Threaded Nut clockwise until the Support Bars on the arbor are just snug against
the inside of the coil.
4. Using the Reel Set Up Chart, (Figure 5), find the “D” dimension that corresponds to the
profile you are using.
5. Slide the arbor left or right to get the correct “D” dimension measuring from the edge of the
coil to the end of the Support Bar on the Threaded Nut side.
6. Finish by rotating the Threaded Nut clockwise until the Support Bars are very tight against
the inside of the coil. Verify that dimension “D” is correct, and re-adjust if necessary. The
Coil and Arbor are now ready for loading. (see LOADING REELED COIL on page 15)

CHAPTER 5
REEL STANDS, REELS, AND EXPANABLE ARBORS
12
Figure 5: Expandable Arbor Set-Up

CHAPTER 5
REEL STANDS, REELS, AND EXPANABLE ARBORS
13
CAUTION: Always use properly rated lifting devices to load and unload coils.
Maximum Capacity / Reel: 3,000 lbs.
Total Capacity for Reel Stand: 6,000 lbs.
1. The reel shafts must rest in the cradles on the reel rack. Keep the cradles lubricated with
synthetic lube to minimize wear. (Figure 6)
2. Use the Hold Down Bars on each cradle to secure the coil and reel to the reel stand during
both operation and transit of the machine. The Hold Down Bracket should be used to keep
the coil from uncoiling too fast during the fabrication of panels. Apply just enough drag to
keep coil tensioned. (Figure 6)
Caution: Do not over tighten Hold Down Bars during machine operation. This will
cause excessive load on the drive and electrical systems and premature failure will result.
Do tighten Hold Down Bars tightly prior to transport of the machine.
3. If a Remote Decoiler is used it should be placed 8 to 10 feet behind the machine. Align it as
close as possible to the Right Side Entry Guide line of fire, making the side of the coil and
reel parallel to the machine. NOTE: The closer the Decoiler and reel are set to the machine,
the more critical this alignment becomes.

CHAPTER 5
REEL STANDS, REELS, AND EXPANABLE ARBORS
14
Figure 6: Expandable Reel Assembly

CHAPTER 5
REEL STANDS, REELS, AND EXPANABLE ARBORS
15
LOADING REELED COIL
Caution:
Always use a forklift or other approved lifting device to load or unload Fixed Reels or
Expandable Arbors loaded with coil.
The Lifting Holes in the Fixed Reel sides are provided to make loading safer and easier.
DO NOT use lifting straps through the lifting holes as the sharp edges may cut the straps.
1. Prepare the reel stand by making sure the Hold Down Bars are in the unlocked and open
Position (Figure 6).
2. Using an approved lifting device, lift the reeled coil into the cradles on the reel stand making
sure that the tail of the coil is in the correct position then remove the lifting device.
3. Rotate the Hold Down Bars (Figure 6) to the closed position and thread the handle onto the
hold down bolt. If you are going to run panel from this coil, tighten the left and right handle
just snug. Final adjustment of tension should be made while running a panel to keep reel from
unwinding material too fast. As the coil becomes smaller, re-adjustment will need to be made.
Caution: Do Not over tighten Hold Down Bars. Drive and/or electrical system failure
may occur.
4. If you are going to transport the machine after loading coil, tighten the Hold Down Bars
securely to keep coil from unwinding during transport, and secure the loose end of the material
to the coil.
5. Before transporting the loaded Expandable Arbor, you should also secure the coil around the
outside edges through the inside diameter using a strap, rope, etc. to prevent the coil from
telescoping (Figure 5).
NOTE: Make sure Hold Down Bars are tightened securely and coil is properly tied off
before transporting machine.

CHAPTER 6
HYDRAULIC SYSTEMS
16
HYDRAULIC SYSTEMS
Maintenance
(Figure 7)
The hydraulic system for your machine is a very durable and reliable system. It must be properly
maintained to ensure trouble free operation and longevity. The factory has installed a 32 weight
AW hydraulic fluid. Because this equipment is used primarily outdoors and exposed to the
elements, it is recommended that the oil be changed annually. Hydraulic oil will degrade if it
remains stagnate in the system for long periods of time. Check the fluid level weekly. It should be
approximately 5” below the top of the filler neck. When checking the fluid level, also note the color
and condition of the fluid. It should be clear in color.
Hydraulic Fluid Troubleshooting
CONDITION
SOLUTION
1
White milky color indicates water contamination
.
Change the fluid
.
2
Dark fluid usually indicates a dirty oil filter
.
Replace the oil filter
.
3 Foamy fluid will cause a noisy pump and slow erratic
operation of the system. The cause is usually low oil
level or air in the system
.
Check fluid level and bleed off air
by pushing the shear down button
and holding for 10 seconds
.
4 Machine runs slow after continuous operation. Check
hydraulic fluid temperature, it should be no more than
140°F (60°C)
.
Allow to cool down. Move to a
shaded area if possible.

CHAPTER 6
HYDRAULIC SYSTEMS
17
Figure 7: Hydraulic System – Overview