Roper Whitney PEXTO 3416 User manual

PEXTO
No. 3416
No. 3418
ROLL FORMING MACHINES
OPERATING INSTRUCTIONS AND PARTS IDENTIFICATION
2833 HUFFMAN BLVD., ROCKFORD, IL 61103-3990 * 815/962-3011 * FAX [phone]
Website: www.roperwhitney.com
Email: [e-mail]
ROPER WHITNEY

SPECIFICATIONS
STANDARD MACHINE
3416 3418
Capacity Mild Steel 14-16 Ga. 16-18 Ga.
Length of Rolls 36” 48”
Diameter of Rolls 3” 3”
Roll Speed RPM 26 26
Roll Speed SFPM 20.4” 20.4”
Working Height 34” 34”
Shipping Weight 1010 lbs. 1150 lbs.
Rear roll has 3 full length longitudinal grooves. 3/8, 1/2 and 5/8 wiring grooves in the bottom and rear
rolls. All three rolls drive. Welded cabinet type stand. Positive chain drive. Ball bearing drive shaft.
STANDARD ELECTRICS
3/4 HP parallel shaft reversible motor with brake and gearhead at 420 rpm. Wired for either 230 volts or
460 volts, 3 phases, 60 hz.
Control panel with push-pull button for on-off 115 volts to control the system. Selection push buttons for
forward or reverse rotation. Indicating lights of 1) red for 115 volts into control, 2) amber light when rolls
are rotating (forming), and 3) white and blue lights indicating direction of the roll rotation.
Anti-trip footswitch to actuate forming roll rotation, and push button “off” will override for an emergency
shutdown.
OPTIONAL FEATURES
Plain rolls with no grooves.
34 rpm or 45 rpm roll speed.
2833 HUFFMAN BLVD., ROCKFORD, IL 61103-3990 * 815/962-3011 * FAX [phone]
ROPER WHITNEY
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ROPER WHITNEY COMPANY
SAFETY RULES
3416 AND 3418
1. WARNING:
Electrical Danger: Misuse or improper installation of machinery connected to a source of
electricity may result in accidental shock that could cause injury or death. Installation must conform
to National Electric Code (Article 250 - Grounding, etc.)
Electrical connections must be made by a trained and qualified electrician. Electrical characteristics
shown on motor plate and control panel must match the power source; and all electrically powered
equipment must be grounded.
2. WARNING:
Mechanical Danger: The power driven forming rolls will rotate in either a clockwise or counter-
clockwise direction. Never place any part of the body including loose clothing near or onto the
rotating rolls. (KEEP HANDS AWAY). Failure to comply will lead to personal body injury.
3. Never clean forming rolls while rolls are rotating -- turn power off to clean rolls.
4. Machine to be operated by authorized personnel who have been trained by their supervisor with the
working and safety features of the machine, and by reading and understanding the Operator’s
Manual.
5. Do not operate power roll former without reading Operator’s Manual and without proper supervisory
instructions.
6. Perform all installation and setup operations before applying power for electrical start-up.
7. Never operate machine with any guard removed; i.e., all required guarding to be installed and
effective. Do not override the safety features of the equipment. Do not remove, paint over, alter, or
deface any machine-mounted warning and instruction plates and signs.
8. Never leave machine running unattended. When not in use, turn off electrical power.
9. Never adjust machine with power on.
10. Avoid accidental start-up.
11. Do not use machine if servicing is required.
12. Use safety glasses and required protective tools.
13. Keep work areas clean and in proper order.
14. Be alert to all potential hazards. Nofify your supervisor whenever you feel there is a hazard involving
the equipment or the performance of your job.
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BEFORE INSTALLING THIS ROLL FORMING MACHINE, READ AND UNDERSTAND THIS MANUAL
AND “SAFETY REQUIREMENTS FOR THE CONSTRUCTION, AND CARE OF USE OF THE ROLL
FORMING MACHINE”.
INSTALLATION
RECEIVING
Immediately upon receiving the roll forming machine, check it very carefully for damage or loss of parts in
transit. Since all equipment is sold F.O.B., the Roper Whitney corp. plant, our responsibility for transit
damage ceases when the transportation company signs the bill of lading indicating that it has received
all of the items listed on the bill of lading in good condition. Report any loss or damage to the delivering
carrier promptly to insure proper handling of your claim.
Question - Distributor or Roper Whitney -- Shortages not appearing on the bill of lading or discrepancies
between equipment received and the order should be reported to Roper Whitney Corp. immediately.
LEVELING
Be sure machine is solid and reasonably level on all four points so there is no camber or twist to the
machine.
If machine is shipped on a pallet, be sure to remove from pallet and place directly on flooring.
Machine must be securely bolted to floor. Bolt holes are provided in base of machine.
CLEANING
In spite of precautions taken in preparing the shear for shipment, dirt and foreign material may
accumulate on machine and other parts during transit, and can cause considerable damage unless
thoroughly cleaned. It is extremely important to inspect and thoroughly clean off any dirt and foreign
material that may have accumulated. DO NOT attempt to blow dirt out with an air hose as this may force
some foreign material into undesirable areas. Remove rust proofing compound with an acceptable
solvent.
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LUBRICATION
The specially compounded lubricants or their equivalent as specified on the data plate furnished with your
machine and the lubrication chart must be used. See Figure 1 for lubrication points.
LUBRICATION CHART
LUBRICANT
COMPONENT Mobile Texaco INTERVAL
BEARING BLOCKS *MOBILE 40 HRS.
GREASE *TEXCLAD
SPECIAL 2
DRIVE CHAIN MONTHLY
* FOR REFERENCE - ANY EQUIVALENT IS ACCEPTABLE
CONNECTING ELECTRICAL SERVICES
1. WARNING: Electrical Danger - Misuse or improper installation of machinery connected to a source
of electricity may result in accidental shock that could cause injury or death. Installation must conform
to National Electric Code (Article 250 - Grounding, etc.)
2. WARNING: Electrical connections must be made by a qualified electrician. Electrical
characteristics shown on motor plate and control panel must match the power source; and all
electrically powered equipment must be grounded.
3. CAUTION: Electricians checking direction of rotation should be cautioned not to operate the
machine until it has been thoroughly checked, cleaned, leveled, and lubricated. For wiring diagram
see Figure 7.
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CAUTION: DO NOT OPERATE MACHINE WITHOUT PROPER INSTRUCTIONS.
Observe all safety rules and regulations. Become familiar with controls and intended operation before
using. MACHINE MUST BE SECURELYBOLTED TO FLOOR and connected to correct source of
voltage, phase and cycles.
WARNING: Electrical danger -- misuse of improper installation of machinery connected to a source of
electricity may result in accidental shock that could cause injury or death. Installation must conform to
National Electric Code (Article 250 - Grounding, etc.) Ground all electrically powered equipment. Ma-
chine to be operated by qualified personnel only.
WARNING: KEEP HANDS AND FINGERS CLEAR OF ROLLS AT ALL TIMES.
Provide point of operation guarding as required to avoid injury. The exact guard needed will be governed
by many factors and may require change when going from one cylinder to another. All required guarding
to be installed and effective before using. Some of the factors involved are: Diameter of cylinder, length
of cylinder, type and gauge of material, direction of feed, number of passes through rolls, etc. Do not
allow clothing or any part of the body (fingers, hands, arms, hair, etc.) to come in contact with the rolls
while the machine is operating. Do not use machine if servicing is required. Use safety glasses and
protective tools when required. Never adjust machine with power on. Be alert to all potential hazards.
Roll Forming Machines are intended for forming a flat sheet of metal into cylinders of various diameters.
Capacity ratings given are based on forming annealed mild steel the full length of the rolls. Definite
capacities depend upon the diameter and length of cylinder to be formed and the number of passes
through the rolls to obtain the desired diameter of cylinder. Stiffness of material and uniformity desired
are factors that must also be considered. When a Roll Forming Machine is overloaded, there will be
excessive deflection at the center of the rolls resulting in cylinders that are bulged in the center.
Become familiar with the location and operation of all controls before using machine. Electrical require-
ments (voltage, phase and frequency) are indicated on the disconnect box and connection to the correct
power source should be made and checked by a qualified electrician.
WARNING: Electrical danger -- misuse or improper installation of machinery connected to a source of
electricity may result in accidental shock that could cause injury or death. Installation must conform to
National Electric Code (Article 250 - Grounding, etc.) The Roll Forming Machine electrics include a
control panel, forward and reversing relays, brake, and footswitch. The control panel is located on the left
hand housing as shown in Figure 3. A close-up of the control panel is shown in Figure 6.
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CONTROLS
ON-OFF BUTTON --------------- Connects 115 vac to the control when the light goes on. The 115 vac is
disconnected when this button is pushed, and the red light goes off. The
electric circuit will permit the off button to override the footswitch.
FORWARD & REVERSE ----- Selects the proper relay to control motor rotation. These two buttons are
BUTTONS mechanically and electrically interconnected so that EITHER forward OR
reverse is switched. Both directions have respective white and blue
lights that indicate the forming roll rotation, i.e., white denotes forward and
blue is reverse.
FORMING LIGHT ---------------- The forming light has an amber color, and is on when the forming rolls
rotate from the footswitch actuation. Conversely, upon switching off the
footswitch, the forming light is turned off.
The forward and reversing relays are located in the reversing magnetic starter box, and will not require
service nor attention by the machine operator.
The brake is part of the electric motor, and will quickly stop the forming rolls when the motor power is
switched off. The motor power can be switched off by either the footswitch or the panel push button
switch. Upon switching the motor power to “on” the brake will automatically release and allow forming roll
rotation.
The footswitch has two anti-trip features -- 1) the foot pedal is covered to prevent someone from stepping
on the switch, and --2) the operator’s foot must extend entirely to engage a “toe” clamp to release the foot
pedal, allowing actuation of the electric switch. Downward foot movement, therefore, switches electrical
power to the motor; and upward foot movement switches the motor power off. The “toe” clamp will reset
to prevent anti-trip when the operator’s foot is removed from the switch.
The gearmotor is mounted on a pivoting bracket. The chain drive adjustment is properly set and should
not be changed. This adjustment is used when removing chain or sprockets. Do not remove chain guard
cover; it must be in position when operating roll forming machine.
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OPERATION OF THE ROLL BENDER
The roll bender machine is designed to initially pinch/grip the sheet material to be formed between the
upper roll (not adjustable) and the lower roll (adjustable upward or downward manually by means of
adjusting screws located in the housings at each end of the lower roll).
The rear (bending) roll is adjustable by means of adjusting screws located in the housings at either end of
the rear roll.
Adjustment upward or downward, on an inclined plane, moves the bending roll toward or away from the
material passing through the pinch (upper and lower) rolls, thus controlling the radius of the cylinder being
formed.
Longitudinal grooves in the rear roll will assist in starting the curvature of the material up and over the rear
roll.
Rear roll position indicators are located at each end of the roll to enable the operator to maintain parallel.
Note: The markings on the indicators are reference marks only and do not indicate any specific radius,
diameter, measurement, etc. and are to be used only as an aide in determining additional adjustments
from a previous position.
Cylinders are formed by inserting the sheet between the gripping rolls as shown in the above illustration.
FIGURE - 2
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Grooves are provided in the right hand end of the lower and rear rolls for forming cylinders with a wired
edge.
Lubrication and visual inspection at regular intervals are required for good maintenance. Use machine
for its intended purpose only and always within rated capacity. Do not operate with guards removed nor
when inspection indicates possibility of malfunction. Correct operation is a necessary safety precaution
and is required to avoid operator injury. Gears, chain drive and motor are fully guarded for operator
safety. Never leave machine running unattended. Keep work area clear and in proper order. Parts list,
drawings, and wiring diagrams are included with these instructions. For repair parts, when needed, give
complete Model No. and Serial No. as listed on the machine nameplate. Identify parts wanted by de-
scription and reference to parts list and drawings.
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OPERATING PROCEDURE
1. Select forward rotation by depressing “Forward” button on control panel (see Fig. 6). White light will
be illuminated! NOTE: This only determines the direction of rotation the rolls will turn when rotation
is actuated by the footswitch. Always select direction of rotation when rolls are not rotating.
2. Insert the sheet material to be formed between the upper and lower rolls. Sheet material should
protrude through the upper and lower rolls until it is in contact with the rear (bending) roll. NOTE: The
amount of material from the gripping point between the upper and lower rolls to the contact point
with the rear roll will usually result in a flat area on the leading edge of the cylinder. To minimize this
flat area (see paragraph #6).
3. Adjust the lower roll upward to slightly pinch the sheet material, making sure the pressure is
approximately the same at both ends. Uneven pressure may cause the material to feed through at
an angle rather than straight through.
4. Adjust the rear (bending) roll upward until the material is curved upward forming an arc. NOTE: It is
advisable to use scrap material of the same gauge thickness as the intended cylinder to experiment
with until the proper cylinder diameter has been achieved. Several adjustments of the rear roll
position may be required to complete a cylinder of acceptable dimensions.
5. To initiate rotation of the rolls, depress the footswitch. (Amber light will be illuminated). This will
cause the material to be fed through the rolls. Before activating rotation be sure the sheet material is
aligned properly.
6. Preforming of the sheet material by inserting the leading edge of the material between the upper and
lower rolls (keep edge of material perpendicular to the rolls) then bending the sheet by hand upward
and slightly around the upper roll will greatly reduce the flat area mentioned in (paragraph #2).
(see Figure - 2).
7. To stop roll rotation, release the footswitch with an upward movement of the operators foot. A very
quick stop will occur, because the engaging brake (nearly simultaneously with the motor power being
switched off) will stop all rotating components. NOTE: For any Emergency Stop -- (roll forming
problem, parts of body or clothing become entangled in the rolls). The rotating rolls will immediately
stop, either from an upward movement at the footswitch - or depressing the “OFF” mushroom button
having a red light.
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3416-3418 FORMING MACHINE
PARTS LIST
REFER TO PARTS IDENTIFICATION CHARTS
INDEX PART # DESCRIPTION INDEX PART # DESCRIPTION
1 767490180 L.H. Housing 26 767630044 Spacer
2 267940025 R.H. Housing Assy 27 767650045 Pivot Screw
3 767220178 Housing Cover 28 (see below) Upper Roll
4 767170022 Rocking Box 29 (see below) Lower Roll
5 767170023 Roll Box 30 (see below) Rear Roll
6 767380024 Large Gear 31 (see below) Cam Shaft
7 767240025 Links 32 767680171 Drive Shaft
8 767200182 Pendent Bracket 33 767060015 Floor Stand
9 767210027 Lifting Cam 34 767220056 Cover
10 767220028 Cover 35 767440187 Chain Guard
11 767210029 Handle Socket 36 767160058 Hinge Pin
12 767380031 Comp. Gears 37 767300059 Pointer
13 767380062 Drive Pinion Gear 38 767030060 Adj. Rod
14 767380032 Conn. Gears 39 767160063 Hinge Pins
15 767380033 Idler Gear 40 687204710 Ball Bearings
16 767680034 Upper Gear Shaft 41 767260064 Collar
17 767680035 Lower Gear Shaft 42 767300065 L.H. Scale
18 767030036 Lifting Lever 767300066 R.H. Scale
19 767220037 Cover 43 767460020 Locking Handle
20 767650173 Rear Adj. Screws 44 767160019 Hinge Pin
21 767650175 Front Adj. Screws 45 625012369 Handle Screw
22 767460040 Lifting Handle 46 660011147 Gearbrake Motor
23 767160041 Pin-Rocking Box 47 767200068 Motor Bracket
24 767680042 Idler Shaft 48 687285524 Sprocket
25 767160043 Lever Pin 49 767980183 Chain
50 687285501 Large Sprocket
3416 STD. 3418 STD.
28 767630007 767630008 Upper Roll
29 767630009 767630010 Lower Roll
30 767630011 767630012 Rear Roll
31 767680005 767680006 Cam Shaft
When ordering Replacement Parts always give Model Number, Letter and Serial Number.
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