ENDURO™ S90 Plate & Stud Rollformer

Operating Manual
1 SUMMARY
This manual describes the operation of the ENDURO™ rollformer. This rollformer
produces a 93.5mm U section plate profile and 90mm C section stud & boxable truss
profiles from 178mm coil ranging in thickness from 0.55mm – 1.2mm BMT. The
rollformer is controlled by an Allen-Bradley PLC and an Advantech panel PC runs
proprietary BlueScope Steel software.

The machine configuration can be quickly changed depending on the skill of the
operator(s). . It is also possible to reconfigure the machine to make 75mm profile but
this requires some punches and other parts to be replaced and is outside the scope
of this manual.

The coil processing is comprised of several sub-sections consisting of a manually

operated in-feed shear, straightener, coil lubricator, plate/stud punch section, truss
punch section, rollforming, printers and shear.

The remote control allows the operator to stack or process the manufactured product
away from the main operator console.

The system has an emergency stop and requires operator intervention to restart the
machine following operation of the emergency stop.

CAUTION!!!
Only persons fully trained and authorized should operate, adjust, or
work on this machine.

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2 TABLE OF CONTENTS
1 Summary .......................................................................................................................... 2
Table of Contents ..................................................................................................................... 3
2 Table of Figures................................................................................................................ 4
3 Glossary ........................................................................................................................... 6
4 Installation ........................................................................................................................ 8
4.1 Moving the rollformer ................................................................................................ 8
4.2 General ................................................................................................................... 10
5 Preparation ..................................................................................................................... 13
5.1 Loading Coil ............................................................................................................ 13
5.1.1 Coil specifications ............................................................................... 13
5.1.2 Procedure ........................................................................................... 13
6 Product toggling.............................................................................................................. 22
6.1 Overview ................................................................................................................. 22
7 Machine Adjustments ..................................................................................................... 25
7.1 Straightener ............................................................................................................ 25
7.1.1 General ............................................................................................... 25
7.1.2 Guides ................................................................................................. 25
7.1.3 Encoder ............................................................................................... 25
7.1.4 Pinch Rolls .......................................................................................... 25
7.1.5 Straightener Rolls................................................................................ 26
7.1.6 Lubricator Adjustment ......................................................................... 26
7.2 Punch Tool Adjustment .......................................................................................... 26
7.2.1 General ............................................................................................... 26
7.2.2 Dimple Hole Adjustment ...................................................................... 26
7.2.3 Proximity Switch Adjustment ............................................................... 27
7.3 Centre Guide Adjustment ....................................................................................... 27
7.4 Rollforming Section ................................................................................................ 28
7.4.1 General ............................................................................................... 28
7.4.2 Custom feeler gauges ......................................................................... 29
7.4.3 Swage Roll Adjustment ....................................................................... 30
7.4.4 Lip Idler adjustment ............................................................................. 31
7.4.5 Flange Idler adjustment ....................................................................... 31
7.4.6 End Flare correction ............................................................................ 32
7.5 Web width adjustment ............................................................................................ 32
7.5.1 Overview ............................................................................................. 32
7.5.2 Calibration ........................................................................................... 32
7.5.3 Procedure ........................................................................................... 33
8 Maintenance ................................................................................................................... 34
8.1 Daily ........................................................................................................................ 34
8.2 Monthly ................................................................................................................... 34
9 Printer ............................................................................................................................. 36
10 Clearing damaged strip from rollforming stands ......................................................... 36
10.1 Overview ................................................................................................................. 36
10.2 Procedure ............................................................................................................... 36
11 Clearing Damaged Coil in or near the shear .............................................................. 39
11.1 Overview ................................................................................................................. 39
11.2 Procedure ............................................................................................................... 39
12 Product inspection sheets .......................................................................................... 41
13 Settings....................................................................................................................... 42
14 Maintenance Schedule ............................................................................................... 43

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3 TABLE OF FIGURES

Figure 4-1 – Rollformer overview................................................................................ 6

Figure 4-2 – Infeed area ............................................................................................. 6
Figure 4-3 – Drive and operator side .......................................................................... 6
Figure 4-4 – Proximity switches .................................................................................. 7
Figure 5-1 – Picking up rollformer by forklift ............................................................... 8
Figure 5-2 – Picking up rollformer at one end ............................................................. 9
Figure 5-3 – Skates .................................................................................................... 9
Figure 5-4 – Rollformer being moved with skates in position at one end .................... 9
Figure 5-5 – Rollformer layout .................................................................................. 10
Figure 5-6 – Coil loading locations ........................................................................... 11
Figure 5-7 – Coil winding directions for ordering positions ....................................... 11
Figure 6-1 – Uncoiler control panel........................................................................... 13
Figure 6-2 – Mandrel is horizontal position with leave facing towards forklift ........... 14
Figure 6-3 – Uncoiler in position ............................................................................... 15
Figure 6-4 – Cutting 40mm champer at beginning of coil ......................................... 16
Figure 6-5 – Feeding coil past encoder .................................................................... 16
Figure 6-6 – Feed coil through to this location .......................................................... 17
Figure 6-7 – Adjusting Siko counters near the shear ................................................ 18
Figure 6-8 – Adjusting Siko punch values ................................................................ 18
Figure 6-9 – Lubricate the shear............................................................................... 19
Figure 6-10 – Length of scrap generated in trusses and wall frames ....................... 20
Figure 6-11 Checking if the profile is square ............................................................ 21
Figure 7-1 Rib in / rib out button ............................................................................... 22
Figure 7-2 Adjusting plates to change between stud and plate ................................ 23
Figure 7-3 Removing the shear ................................................................................ 24
Figure 7-4 Careful clean the shear area with a cloth to remove dust and any debris 24
Figure 8-1 Straightener and in-feed guides .............................................................. 25
Figure 8-2 Siko counters .......................................................................................... 26
Figure 8-3 Proximity Switch adjustments .................................................................. 27
Figure 8-4 Marking location of bolt for different product thicknesses ........................ 28
Figure 8-5 Adjusting gap between the rolls .............................................................. 29
Figure 8-6 Feeler gauge ........................................................................................... 30
Figure 8-7 Turn off hydraulic valve to keep swage roll in raised position .................. 30
Figure 8-8 Lip and flange idler .................................................................................. 31
Figure 8-9 Lip idler adjustment ................................................................................. 31
Figure 8-10 End flare adjustment ............................................................................. 32
Figure 11-1 Removing the caps................................................................................ 37
Figure 11-2 Measure and record the gap in the idler before loosening ...............Error!
Bookmark not defined.

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Safety

WARNING!!!

Significant hazards exist with machine operation that could result in

severe injury, loss of limbs, blindness or death.

NOTE: Caution must be exercised at all times to ensure the safety of the operator
and people around the machine.

Management of the machine is crucial in minimizing significant existing hazards,

which include but are not limited to:

 Coil handling danger

 Coil unstrapping danger
 Sharp edges of the coil, burrs and metal splinters
 Material flow into and out of the machine
 Crushing danger between rolls & punch parts
 Hydraulic fluid under pressure
 Moving parts in shears
 Electrical shock

WARNING!!!

All guards must be in place while the machine is in operation.

Many pinch points are present within guarding due to formers, chain, gears and other
moving parts.

Guards are only to be opened by authorized personnel.

The machine should be electrically isolated if people are working within the guarded
area.

Guards must be secured when not under the supervision of authorized personnel
and always on completion of work.

Ensure that hydraulic pressure has been released before attempting to adjust
punches or shear.

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4 GLOSSARY
Human machine interface Flattening rolls
(HMI)

Shear Rollforming Stiffening rib

Printer

Figure 4-1 – Rollformer overview

Encoder Manual shear
Wall punches
Straightening
Truss punches rolls

Figure 4-2 – Infeed area

Drive side

Operator side

Figure 4-3 – Drive and operator side

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Proximity (“prox”) switch – A sensor that indicates whether a moving part is in the
correct position. A small orange light indicates whether the proximity switch is active
and this is fed back to the HMI as an error.

Figure 4-4 – Proximity switches

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5 INSTALLATION
5.1 Moving the rollformer

The rollformer can be moved by picking the rollformer up in the middle as is shown in
the photo below with a minimum 5t forklift. The forklift must pick up the rollformer
from the underside with the tynes positioned near the vertical members of the
rollformer chassis. Great care is required to make sure that the rollformer is properly
positioned on the tynes, and the forklift is moving around slowly and as close to the
ground as possible. All personnel should be clear of the rollformer when this is being
done.

Timber chocks need to be put under the rollformer before the rollformer tynes can be
removed.

Figure 5-1 – Picking up rollformer by forklift

The rollformer can be moved around with a 3t forklift by picking up at one end and
putting skates at the other end. Examples of picking up the rollformer and skates are
shown below.

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Figure 5-2 – Picking up rollformer at one end

Figure 5-3 – Skates

Figure 5-4 – Rollformer being moved with skates in position at one end

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The 3t forklift needs to lift the rollformer off the skates once the rollformer is in
position.

5.2 General
The ENDURO™ rollformer is shipped loaded with coil to prevent the hardened steel
tools from being damaged during transit. The coil needs to be carefully driven out in
manual mode before before new coil can be loaded into the machine. If the transit
material has inadvertently become damaged during transit and it no longer fits
cleanly through the shear aperture, it may be necessary to temporarily remove the
shear and override the top shear proximity switch by taping a small piece of metal
over the tip.

Step 1:Positioning the rollformer

Position machine on floor, allowing at least 800mm all round for maintenance and
with the turned feet fitted under all 6 jacking screws. Sufficient space should be
provided for forklift access to both load and unload coils from the rollformer. This can
be done from all 3 sides of the tilt up uncoiler providing the forklift tynes are long
enough to extend over the uncoiler.

The layout of the rollformer is shown below.

Figure 5-5 – Rollformer layout

Level the machine ensuring all jack points are taking weight, and secure the machine
in position using anchor bolts (not provided).

Step 2: Positioning the decoiler

Position the decoiler at least 2750mm– and preferably 3500mm - from the in-feed of
the rollformer. Orientate the rollfomer so that the coil will spool from the top of the
uncoiler in a straight line into the rollformer. The loading direction on the uncoiler
should be determined to whether the uncoiler will be loaded on one side or the other,
or from the rear.

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 Loading from drive side

Loading
from
rear

Figure 5-6 – Coil loading locations

Loading from operator side

Note: when ordering coil from your supplier, you will need to advise which direction
the coil should be wound in. The direction is determined by the uncoiler setup. Coils
that are supplied underwound can be operated with strip coming off the underside of
the coil. Refer to the HMI manual for instructions on how to do this.

Figure 5-7 – Coil winding directions for ordering positions

When positioning the uncoiler, the edges of the coil should also align with the in-feed
guides. A good way to align the decoiler is to cut off a 7-8m length of coil, feed it into
the machine until it gets to the second set of guides and bring the decoiler up to the
4-5m tail extending from the front of the machine. This should give an excellent
indication of position and angle. Check by removing coil and turning end for end in
case coil has camber.

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Securely fix the decoiler in position by bolting to the floor with appropriate anchors.
This must be done to prevent the uncoiler from potentially moving in the event of
decoiler malfunction.

Step 4: Laser positioning

Position the laser sensor above the lowest point of the coil when it has sagged to
approx 150mm from the ground. Note that the final location & bolting down usually
can’t be done until after machine has been loaded with coil.

Step 5: Check the hydraulics

The machine is shipped with Morris Triad 46 hydraulic and the level should be
checked that it fills the sight glass before connecting to the electric supply. The
ENDURO™ rollformer is fitted with an oil cooler and a 24V DC fan which starts to
operate when the oil temperature exceeds 45°C.
Step 6: Check the electrics
Wire with 3P+N+E to terminals provided, machine is supplied with isolator.
Main Drive Motor 7.5kW
Hydraulic Pump Motor 4kW
Decoiler Motor 4kW

Bump check rotation direction of all motors.

Power pack rotation is CLOCKWISE looking at fan end of motor.

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6 PREPARATION
6.1 Loading Coil

Warning
Protective gloves should be worn when handling raw coil or finished product.

6.1.1 Coil specifications

Width 178mm
Thickness Range 0.55- 1.2mm BMT
Product TRUECORE® steel
Tensile Range G550
Max coil mass 1.5t
Pack type Bore vertical – WVA??

Refer to Figure 5-7 for details of the coil winding direction.

6.1.2 Procedure

Step 1: Set up the ENDURO™ rollformer for coil loading

Loosen & remove the adjustable leaves and using the control switches (refer Figure
6-1),tilt the mandrel to the HORIZONTAL position. Again using the control switches,
rotate the mandrel backwards until the fixed leaves stop automatically aligned
parallel with the direction of loading as shown in Figure 6-2. CLOSE the mandrel to
its smallest diameter.

Emergency stop

Opens and Rotates uncoiler

closes the backward and
mandrel forward

Tilts the uncoiler

Figure 6-1 – Uncoiler control panel from horizontal to
vertical

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Figure 6-2 – Mandrel is horizontal position with leaf facing towards forklift

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Step 2: Loading coil
Using a forklift, load the coil onto mandrel (check that coil will spool from top when
tilted vertical).

Mandrel
Leaf

One strap of
banding left on

Figure 6-3 – Uncoiler in position

Cut and remove any radial banding from around the coil that can be removed while
the mandrel is contracted , keeping one strap around the circumference of the coil.

Note: Ensure that full PPE is worn while removing banding from the coil, including
gloves, safety glasses and face shield as the steel banding is sharp and will
clockspring once cut.

Using the control switches, OPEN the mandrel until the relief valve activates.
Replace & tighten the adjustable leaves. Tilt the mandrel back to the VERTICAL
position. Remove circumferential banding and remaining radial banding from the coil,
taking care not to allow the coil to clockspring..

Jog mandrel FWD using the control switches until sufficient coil is available to reach
the in-feed pinch rolls when the loop is nearly touching the ground.

Step 3: Prepare the strip ends

If the tag end of the steel coil is not smooth and flat, cut approximately 40mm
chamfers on each corner with tin snips to assist feeding through the punch sets If the
coil was last cut with the integral in-feed shear no further preparation should be
necessary.

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Figure 6-4 – Cutting 40mm champer at beginning of coil

Step 4: Load the ENDURO™ rollformer

Adjust the machine settings to match the coil thickness and desired profile to be run.
Manually feed coil into the machine. Push strip past the encoder to the pinch rolls,
withdraw the coil slightly, then give a short sharp shove forwards so that it forces its
way between the pinch rollers. Take care to ensure that the steel strip feeds under
the guides.

Figure 6-5 – Feeding coil past encoder

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 Strip must be jammed into the
first motorised rolls.

Figure 6-6 – Feed coil through to this location

Step 5: Set up the ENDURO™ rollformer

Use the manufacturers settings guide to ensure that each stage is correctly set up for
the profile that is being run. If changes are required, all Siko counters (both drive side
and operator side) will need adjusting. Different values are required depending on
whether C or U sections are being rolled and the values will differ on gauges.

For the Siko counters close to the exit of the rollformer, loosen the locking handle,
then using a 12mm AF spanner, rotate until the counter reads the specification
required. Once complete, tighten the locking handle.

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 Locking
handle

Adjust
value

Figure 6-7 – Adjusting Siko counters near the shear

For the Siko counters close to the rollformer entry, loosen the screw at the top of the
counter using a 4mm Allen key. Use an 11mm AF spanner to adjust the settings. Re-
tighten using the Allen key. Values may need to be changed after each coil change
over as different coils can have slightly different adjustments.

Figure 6-8 – Adjusting Siko punch values

Remove the polycarbonate cover from the end shear and oil the holes in the die set.

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Figure 6-9 – Lubricate the shear

Once complete, replace the polycarbonate cover.

Step 6: Feed strip through

Carefully jog the machine forwards while watching the coil progress though the
various stages of the machine confirming each stage is correctly set for the profile
that is being run.

For the C section, ensure that the “Rib in” button is selected on the HMI. For the U
section, “Rib out” should be selected.

The distance that strip is fed through the rollformer will determine the amount of
scrap generated once orders are loaded into the rollformer. The amount of scrap
generated will be between the position the strip is stopped before the order is loaded
and the position of the first punch that is activated. A small amount of strip should be
cut off to check the quality of the profile. The further the strip is fed through the
rollformer before the order is loaded, the more profiled product is made to do quality
checks.

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 Scrap generated at the beginning
of coil for trusses

Scrap generated at the beginning

of coil for wall frames

Figure 6-10 – Length of scrap generated in trusses and wall frames

Once the strip is fed into the rollformer, go to “Edit order” in the HMI and select “Clear
Production”. This will reset all values on the main screen to 0. Failure to do this
means the rollformer will run backwards when an order is run. After selecting “Clear
Production”, load the orders that are required to be made.

Take particular care as the product reaches the shear. The strip must be close to the
desired profile or it will not pass through the shear. Once the product has exited the
rollformer do a quality control check following the QC procedures and complete the
Product Inspection Record ENDURO-QA-001 or ENDURO-QA-002 depending on
whether the profile is a stud or plate. Take a cutting and using a protractor, ensure
that the angles are at 90O. If the profile does not meet the tolerances of the Product
Inspection Record, refer to Section 7 for instructions on how to adjust the rolls. This
check should be done after every 600m.

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Figure 6-11 Checking if the profile is square

Review the Product inspection records for all checks required. Any product
manufactured out of tolerance should be noted.

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7 PRODUCT TOGGLING
7.1 Overview
Adjustments need to be made to the ENDURO™ rollformer to change from
producing one profile to another. to swap between 90mm ribbed C profile and 93.5
un-ribbed U profile. It is recommended that the adjustments are made when the
ENDURO™ rollformer is clear from any strip. .

Step 1: Rib In/Out

With the hydraulics running toggle the HMI button to raise or lower the ribs as
required.

Rib in/ rib

out button

Figure 7-1 Rib in / rib out button

Step 2: Web width adjustment

Loosen the 4 large locking handles at each end of the triple idler bases near the
shear end of the machine.

Slide both bases inwards for 90mm profile or outwards for 93.5mm profile.
The bases only move 1-1.5mm at each end but a clunk should be heard as the bases
come up to the appropriate stops. This can be checked by looking at the two gauges.
For the C profile, these should be touching, but for the U profile, they should be
3.5mm apart at the shear end and about 2mm apart at the other end.

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 Gauge to
confirm if plate
in or out

Large
locking
handle

Figure 7-2 Adjusting plates to change between stud and plate

Retighten the large locking handles.

Step 3: Minor adjustments

Re-adjust the dimples, quad dimples, lip idlers and the last flange idler counters to
the setting specified in the calibration chart. Refer to the Appendix for the correct
values.

Step 4: Change the shear

Ensure that the hydraulics are turned off when the shear is in the open position. See
Figure 7-3.

Raise the clear polycarbonate guard which interlocks the rollformer. Loosen and
remove the two M10 cap screws underneath and just beside the shear chute and
slide the shear towards you to remove. If this sticks, light side to side taps with a
mallet the end of the shear chute is usually sufficient to release it.

Note: Care must be taken when handling the shear as it weighs approximately 17kg.
During handling, be careful to hold the shear by the base and not the top blade which
can be easily removed.

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 Loosen
these
bolts

Figure 7-3 Removing the shear

Clean the floor of the shear frame of swarf and other foreign matter including under
the lip at the rear using a cloth. Clean the bottom face of the alternate shear and
around the notch in the top. Fit the shear taking care to engage the notch correctly on
the spigot. Keeping the area where the shear sits, clean and lightly lubricated, will
ensure that the shear can slide in and out easily. It is recommended to us an an air
hose to clean the shear area each day.

Figure 7-4 Careful clean the shear area with a cloth to remove dust and any debris

Carefully tap fully home using a mallet remembering if it takes force to fit, it will take
more force to remove.

Re-fit and tighten the M10 cap screws. Refit the polycarbonate guard.

Reset the machine.

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8 MACHINE ADJUSTMENTS
Machine adjustments may be required from time to time if the profile becomes out of
tolerance.

8.1 Straightener
8.1.1 General
All adjustments of vertical settings need to be made carefully & evenly on both the
operator and the drive side of the rollformer.

Straightener
rolls Pinch rolls

Encoder

Lubricator

Infeed Guides

Figure 8-1 Straightener and in-feed guides

8.1.2 Guides
The infeed guides should be a snug fit on the coil. It is recommended that only the
drive-side infeed guides are adjusted for coil width. Adjusting the operator-side
guides may result in a long lip on the short flange which will make boxing very
difficult.

8.1.3 Encoder
The encoder pressure wheel needs to be set at sufficient force that it is difficult to
turn by hand.

8.1.4 Pinch Rolls

The pinch rolls need to grip the coil with sufficient pressure to drive the coil through
the straightener rolls.

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8.1.5 Straightener Rolls
The coil should exit the straightener straight and near horizontal. If it curls up, loosen
the second straightener roll vertical adjustment bolts approx ½turn. Re-check by
reversing the coil out of the straightener rolls. Similarly, if it curls down, tighten them.

8.1.6 Lubricator Adjustment

Note: this is not required if running TRUECORE® steel which has special
coating on it that negates the requirement for lubricant.

The sheet lubricator is controlled by a valve that should only open when the machine
is running AND turned on in the HMI so stationary adjustment is not practical. Fill the
lube tank with soluble oil mixed at a ratio of 5%-10%. A watering can with the rose
removed is ideal for this job.

The two outer (copper) needle valves control lube flow to the inside of the top roller.
The two inner (black) needle valves control lube flow to the bottom roller.
The balance of the (gold) needle rollers control the flow to outside of the top roller. It
is recommended to only apply lube to the centre 2/3 of the coil. Gold needle valves
outside this area should be turned off.

Ideally no lube should reach the far end of the machine either on the product or via
the drip trays. If the product is still wet when it reaches the shear it will be difficult for
the inkjets to print correctly.

8.2 Punch Tool Adjustment

8.2.1 General
All Siko counters are fitted to shafts with a 1mm pitch right hand thread and each
right hand digit represents and increment of 1/10 of a millimetre. Therefore turning
the shaft one full turn anti-clockwise results in the adjustable item moving exactly
1mm away from the counter and the numbers will change from 0000 to 0010.

Figure 8-2 Siko counters

8.2.2 Dimple Hole Adjustment

For each product and coil thickness the position of both sets of dimples needs to be
adjusted according to the calibration chart.

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To adjust each setting, loosen the 8mm grub screw and rotate the adjustment shaft
using the 11mm ratcheting ring spanner until the counter matches the calibration
chart. Re-tighten the 8mm grub screw.

All counters should be brought up to the mark in an anti-clockwise direction so if a

clockwise adjustment is required; over-adjust by at least ½ a turn and bring back to
the setting.

8.2.3 Proximity Switch Adjustment

It is important that the punch proximity sensors are correctly set. If the top proxes are
set too low the machine may try to advance before the punch is fully out of the
material. If the bottom proxes are set too high the punch may not complete or slugs
may be pulled back up thru the die aperture. Bottom proxes on ALL punches that
make dimples should be set with material in the machine.

Proximity Switches
Figure 8-3 Proximity Switch adjustments

To check, put the machine into diagnostic mode and select to punch to test. For the
proxes to work correctly they should be approx 0,5-1,0mm clear of the surface they
are sensing. The top prox is set first by loosening the M6 hex head bolts and sliding
the mount bracket up or down so the prox will be activated within 1mm of the punch
reaching the top of its stroke. Activating diagnostic mode on the control console and
selecting a particular punch, then holding down the punch button on the remote
control keeps the punch at the bottom of the stroke so the bottom prox setting can
be checked that it activates within the last 1mm of its travel. As a rough guide the
prox should be approx half covered by metal for activation to occur. To adjust, loosen
the M6 hex head bolts on the prox sense bracket attached to the end of the punch
tool and slide up or down. If more travel is needed there is a second set of mounting
holes for the punch sense bracket as well as a secondary location for the lower prox.

8.3 Centre Guide Adjustment

The centre guides should be a snug fit on the coil and adjusted in unison with the
straightener guides. Adjusting bolts are the same pitch so the same number of flats
or turns can be used.

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8.4 Rollforming Section
8.4.1 General
From time to time it may be necessary to alter rollformer settings, when this is done
to ensure that a record is taken of original settings and that changes are methodical
such that they can be undone if necessary. See Figure 8-4.

Figure 8-4 Marking location of bolt for different product thicknesses

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Former clearance adjustment is carried out with no material in the machine and
feeler gauges used to ensure even clearance all round the working surfaces. Most of
the rollforming section is set to roll the maximum material thickness that the customer
will run. When running thinner material it should only be necessary to adjusting the
(first) swage rolls to obtain the desired rib dimensions and the last roll to ensure the
last of the coil is driven from the machine. This check can be done by placing a feeler
gauge of the same thickness as the coil being rolled between the rolls and ensuring
there is a tight fit. If it is too tight or loose, the height of the top rolls can be adjusted
by turning the bolt on top of the caps.

Figure 8-5 Adjusting gap between the rolls

The position of the bolt should be recorded so the gap can be re-instated, if required.
This also helps speed up gauge changes.

If the product changes suddenly or over a long period of time carefully examine all
changes or adjustments made to ensure they have been carried out correctly.

8.4.2 Custom feeler gauges

A feeler gauge can be made from the material to be rollformed and is usually more
convenient to use than traditional feeler gauges and shown in Figure 8-6. After
cutting it from the coil stock, remove all burrs and sharp corners. Radius the corners,
feather the edges and check for flatness at the gauging end. The tip should be 8 -
12mm wide. Folding facilitates easier use.

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Figure 8-6 Feeler gauge

8.4.3 Swage Roll Adjustment

The swage rolls can only be adjusted for clearance with the swage roll hydraulically
raised and NO material between the rolls. Typically, when the guards are raised all
power is cut and any stored hydraulic power is released. In order to do a check
between the swage roll with the roll in a raised position, the accumulator pressure
needs to be dumped while the machine is still powered up and the hydraulics are on.
This is done by removing on of the lower guards to gain access and opening the
manual dump valve on top of the hydraulic tank, and then opening an upper guard.

Figure 8-7 Open accumulator dump valve to keep swage roll in raised position

Measure the gap between the rolls using feeler gauges and compare with the
calibration chart. It is critical that both sides are adjusted evenly and measured
carefully on the flat area just inside the lip fold on BOTH sides of the machine. Over-
tightening the swage rolls will cause the product to bow up.

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 Lip idler Flange idler

Figure 8-8 Lip and flange idler

8.4.4 Lip Idler adjustment

To adjust the lip idler, loosen the locking handle and using the 12mm ratcheting ring
spanner, wind the adjuster until the setting matches the calibration chart and tighten
the handle.

Locking handle

Adjuster

Figure 8-9 Lip idler adjustment

8.4.5 Flange Idler adjustment

Only the last flange idler on each side should require adjustment between different
products.

To adjust the lip idler loosen the locking handle and using the 12mm ratcheting ring
spanner, wind the adjuster until the setting matches the calibration chart and tighten
the handle

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8.4.6 End Flare correction
Mounted to the infeed side of stand 14 is the end flare correction mechanism which is
only active when making 90mm C section profile.
To set these back to a neutral point, adjust all four outer rollers back out of the way
and carefully fill the machine with C section profile. Adjust the outer rollers back in
until they just touch the top of the flanges.
To correct end flare, run profile with notched flanges. The rollers closest to the shear
have more effect on leading edge flare and vice versa for trailing edge flare. Only
make small adjustments of 1-2 flats at a time. Check both leading and trailing flare
before making further adjustments.

Adjusting
bolts

Figure 8-10 End flare adjustment

8.5 Web width adjustment

8.5.1 Overview
The framing machine is designed to roll material varying in thickness from 0.55 to
1.2mm and produce a C section profile with a NOMINAL web width of 90mm. To do
this the machine should be set so that it produces a 90mm profile when using 1mm
material. This means that thicker material will make product slightly wider than 90mm
and thinner material make product slightly less than 90mm.

8.5.2 Calibration
Set the machine to make C profile with 1mm coil and measure the web width
ensuring that both flanges are at 90°. If the product measures significantly less than
90mm, both Raft 2 Base Plates need to be adjusted symmetrically outwards each by
half the required distance.

To make the product 1mm wider each Raft 2 Base Plate need to be adjusted
outwards 0.5mm. The adjusting screws are 1.25mm pitch so this approximates to 2
flats.

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8.5.3 Procedure
1. Loosen both Tension Levers on the first base to adjust.
2. Loosen both outer locknuts
3. Tighten both outer set screws by the "half" adjustment
distance [2 flats] (Note: it may be necessary to loosen the inner set
screws to achieve this)
4. Tighten both outer locknuts
5. Loosen both inner locknuts
6. Nip up both inner set screws so the Base Plate is laterally restrained

Check the base plate is parallel to the machine base by placing a 300mm steel ruler
or similar straight edge tangential to the Ø40 chrome shafts and measuring the
distance to the machined face of the Raft 2 Base Plate adjacent to each adjusting set
screw. This "offset" should be in the range of 4-6mm however it need to be exactly
the same at the both ends. Note this dimension.

7. Tighten the Tension Levers

8. Loosen the INNER set screw closest to the infeed by 3 flats (½ turn)
9. Tighten its locknut
10. Loosen the INNER set screw closest to the shear by 9 flats (1½ turns)
11. Tighten its locknut

Note: the steps 8-11 allow each raft to become 3,5mm wider at the shear end AND
out-of-parallel when making the 93,5mm U section

Repeat steps 1-11 for the other Raft 2 Base Plate ensuring the resulting "offset" is
the same as the first.

Check all M16 washers under the M16 Nylocs are a sliding fit and on the edge of
binding up. Adjust as necessary. If in doubt tighten hard the Nylocs at the shear end
of both Base Plates after changing between profiles.

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 9 MAINTENANCE
9.1 Daily
The machine operator should look and listen for changes in the forming process,
machine operation and product quality. If changes appear, such as the shear cutting
ragged, or oil leaking etc., investigate and take appropriate action. Issues of machine
and environmental safety should be actively monitored and action taken as
necessary.

Table 1: Daily Maintenance

Parts Appropriate Action
Punch Tools Lubricate guide bushes with oil (36)
Shear Oil holes at top of shear blade (2)
Grease shear infeed area
Hemming slideways Grease with Multipurpose type grease
Shear Remove dust/ swarf from shear using air gun
Ink wastage bottle Check to ensure not overflowing
Printer Check there is sufficient ink and cleaner and refill if
necessary
Scrap bins Empty scrap bins

9.2 Monthly
Maintenance of specified parts should be carried out according to table 2 below. Use
a Lithium based EP grease for general greasing

Table 2: Monthly Maintenance

Parts Appropriate Action Requirement
Rollformer Clean rollformer removing swarf and slugs
Decoiler leaves Grease nipples on slider blocks (4)
Decoiler main shaft Grease nipple on frame (1)
Decoiler pivot Grease nipple on shaft ends (2)
Decoiler cylinder Grease nipple on eye (1)
Decoiler power pack Check oil level - Morris Triad 46
Straightener roll Grease nipples on shaft ends (10)
Swage cylinder & link Grease nipples on pin ends (4)
Eccentric shaft Grease nipples (4)
Eccentric ends Grease nipples (4) (obscured)
Ink and cleaner Check ink and cleaner level.
Empty waste bottle
Swage rolls Grease nipples on bearing blocks (8)
Idlers Grease nipples on shafts (8)
Drive chains and gears Lubricate with spray on Chain and Gear
Lube
Drive chain adjustment Check and adjust to remove excessive
slack

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Parts Appropriate Action Requirement
Drive gearbox Check oil level
Hydraulic power-pack Check oil level - Morris Triad 46

Table 3: Other Maintenance Maintenance

Parts Appropriate Action Timing
Hydraulic power-pack Replace hydraulic oil as required (Every 1 1 – 3 years
to 3 years) depending on usage and
temperature. Note: hydraulic oil can be
checked by oil suppliers to confirm oil
quality.
Inkjet printer Replace ink filter Every 30 litres of
ink or annually,
whichever comes
first

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10 PRINTER
Refer to the maintenance and cleaning procedures in the Matthews Printer Manuals
for further information

11 CLEARING DAMAGED STRIP FROM ROLLFORMING

STANDS
11.1 Overview
The ENDURO™ rollformer has the capability to produce a highly punched profile.
This means that from time to time the resulting profile will be so segmented that it will
not run smoothly through the machine and will crash. This will usually occur around
the shear, but can also occur throughout the length of the rollformer. In these
circumstances, the strip will need to be manually removed from the rollformer.

To facilitate removal of damaged coil from the ENDURO™ rollformer after a crash it
may be necessary to remove or loosen the caps from the stands. This will allow the
top tooling to rise up on the springs and release its grip on the product. Additional
clearance between tooling rolls can be gained by inserting wooden blocks or similar
between the bearing blocks and in some cases lifting the complete upper tooling off
the Ø40mm chrome shafts may be required.

11.2 Procedure

Step 1:
Raise both main guards to approx 90° and open the accumulator dump valve located
on top of the hydraulic tank. On the rollforming stand to be partially dismantled,
loosen the M12x50 cap screws on the drive side of the stand several turns using the
10mm AF Allen key. Repeat on the operator side. The top shaft will rise as the
screws are progressively loosened.

Remove all four cap screws.

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 Cast iron
caps

Cap
screws

Springs

Figure 11-1 Removing the caps

Remove the cast iron caps and store or mark them so that they can be replaced in
exactly the same location.

If additional clearance is required, raise the top shaft and insert wooden packers
between the bearing blocks. It may be convenient to temporarily remove the springs
and store in a safe location. The top assembly weighs approx 35-40kg and can be
lifted comfortably with a person on either side of the machine.

In some situations it may be necessary to remove to the top tooling altogether to gain
better access. If this is the case it will be necessary to temporarily shift the hydraulic
tubing to the rear (shear) manifold out of the way. This can be done by removing the
M12 cap screws that retain the tubing clamp brackets and removing the two M10x25
cap screws that mount the rear 3-way manifold to the guard frame, then swinging the
tubes out of the way but taking care not to bend the pipes excessively while removing
the upper tooling. Failure to adequately support the weight of the manifold at all times
may result in damage to the tube or the fittings.

It is also necessary to loosen the idlers to allow damaged strip to be removed. This
can be done by adjusting the idler to substantially increase the clearance between
the rolls.

Step 2:
Using a hacksaw, good quality tin snips (Gilbow brand or similar), cut the damaged
strip. If access allows it may be possible to cut the product with an electric nibbler.
Use of an angle grinder fitted with a cutoff disc is STRONGLY discouraged.

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Step 3: Re-assembly
Replace any top tooling has been lifted off the shafts. Ensure springs are in pockets
before replacement. Stand 2 has 89mm springs, all others have 76mm springs.
Ensure bearing blocks in top tooling assembly have the spring pockets underneath.
Bearing blocks must be started evenly and squarely and carefully tapped down
evenly using a soft faced mallet. This may be easier if both M8 grub screws are
removed from the operator side bearing but beware this allows the bearing to slide
completely off the shaft. If binding occurs, carefully tap lowest points upwards until
they are free. Ensure springs engage in upper pockets.

Replace the cap in original location with writing facing outwards. Refit M12x50 cap
screws and tighten in stages starting on the operator side. When tightening the drive
side, ensure gears are correctly in mesh. Failure to do so could result in breakage of
the caps. Replace any grubs screws that have been removed from the bearings.

For all stands EXCEPT the first and last, check vertical clearance between the rolls is
equal to maximum material thickness to be rolled. Clearance on first stand as per
setting chart. Clearance on last stand to be current material thickness.

Step 4:
Return rear manifold to original location and re-fit screws and tubing brackets.

Check all parts have been re-assembled correctly and clear away tools.

Step 5:
Close the accumulator dump valve and close main guards.

Step 6:
Reload the machine with coil.

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12 CLEARING DAMAGED COIL IN OR NEAR THE SHEAR

12.1 Overview
Assuming the profile crashed in the shear there is different way of clearing the
machine. This method has been used with varying degrees of success but it is
stressed that this must be used with caution; only at the lowest possible speed and
preferably with several observers stationed down the machine looking for problems
when inching.
The method involves effectively locking the product part way down the machine and
using the front end in reverse to pull the concertina straight. The method is more
effective in thinner gauges which are more susceptible to this problem in the first
place

12.2 Procedure
Adjust all 8 overfold idlers to their maximum opening. See 11.2 for details on how to
do this.

Remove the shear and override top prox so machine thinks shear is in place.

Loosen M12x50 cap screws 2 or 3 turns on all stands EXCEPT the first stand which
puts the ribs into the web.

Note: The top screws should never be adjusted during this process as this could
affect the profile being run.

The idlers may also need to be loosened to allow strip to pass through unimpeded.
Refer to Section 11.2 for information on how to do this.

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Stake or clamp the product part way down to a solid part of the machine. A large
metal rod through a service hole as per photo below can be used to stake it even if it
necessary to manually drill the hole though the product.

Staking the coil

It is advisable to remove the top of the guide between the last two punches and cut
the coil with tin snips. Also unscrew the star knobs then remove the guides adjacent
to the rib forming rolls so that you can progressively cut out coil as it is extracted
rather than forcing it back through the punches. With the coil cut between the two
punches loosen the cap screws holding down the straightening rolls and pinch rolls
so the straightener no longer has drive on the coil.

If currently running plate section engage the rib forming rollers

Very carefully inch the machine backwards until the stake touches the tooling of the
stand acting as the brake or the clamped section comes under load.

Continue inching the machine backwards carefully to attempt to pull out the
concertinas while watching for tearing of the stake along the product.

With a bad crash there may be many concertinas through the machine. If the far end
of the coil is staked, there is a possibility that some folds may come back through
rolls set at material thickness which is a major problem. To avoid this it may be
necessary to stake the coil nearer the swage roll to ensure that the folds are pulled
out in the order least likely to cause a problem

If there is insufficient grip to pull the folds out retighten the M12x50 cap screws of
stand 2. Re-test and tighten additional stands at the front of the machine until you
either have enough grip to pull out most of the folds or rip the stake through the
product.

Once the coil is approximately straight re-tighten all M12x50 cap screws taking care
that all gears mesh correctly and inch the machine forward to drive product out the
shear end of the machine. Any product that is too badly deformed should be
manually cut out.

When the machine is clear of product, reset shear top prox and re-fit shear.

Using a 5mm Allen key as a gauge, set idlers 11 to 5mm as per attached drawing. In
a similar manner set idlers 9 to 6mm and adjust other idlers as per setting chart and
adjust status of rib-in if necessary.

Re-fit guides adjacent to rib rolls and re-assemble guide between last two punches
Re-tighten screws on straightener & pinch rolls and re-load machine with coil.

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13 PRODUCT INSPECTION SHEETS

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14 SETTINGS

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15 MAINTENANCE SCHEDULE

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© Angus Robertson Mechanical Ltd
21 November 2011

ENDURO™ is a trademark of BlueScope Steel Limited. TRUECORE® is a registered trademark of BlueScope

Steel ABN 16 000 011 058

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