KR-SERIES (KR-56A, KR-50A, KR-60A) Gutter Forming Machines

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KR-SERIES (KR-56A, KR-50A, KR-60A)

Gutter Forming Machines

GENERAL OPERATING AND MAINTENANCE INSTRUCTIONS

Knudson Mfg., Inc.

10401 W. 120

th

Ave.

Broomfield, CO 80021

USA

(303)

469-2101

(tel)

Version:

4.0

(303)

469-7994

(fax)

Date:

12/02

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Change Record Page:

Document: KR-SERIES Manual

Date Change Authorization

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TABLE OF CONTENTS

1. PROFILE SPECIFICATIONS...4

2. MACHINE SPECIFICATIONS ...14

3. TERMINOLOGY ...18

4. REQUIRED TOOLS AND EQUIPMENT...20

5. INSTALLATION ...21

6. SETUP AND OPERATION ...25

7. ADJUSTMENT AND TROUBLESHOOTING...34

8. CHANGEOVER PROCEDURES ...44

9. MACHINE MAINTENANCE...48

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1. PROFILE SPECIFICATIONS

1.1. PROFILE SPECIFICATIONS 1.1.1. Profiles

Refer to the enclosed profile drawings at the end of this Section:

5-in K-Style OG Gutter with Straight Back (KR-50A, KR-56A) 5-in K-Style OG Gutter with Free Float Hook (KR-50A, KR-56A) 5-in K-Style OG Gutter with 1-in Flange (KR-50A, KR-56A) 6-in K-Style OG Gutter Straight Back (KR-60A, KR-56A) 6-in K-Style OG Gutter with Free Float Hook (KR-60A, KR-56A) 6-in K-Style OG Gutter with 1-in Flange (KR-60A, KR-56A) 6-in K-Style OG Gutter with 2-in Flange (KR-60A, KR-56A)

1.1.2. Material Types

Steel, Galvanized Steel, Pre-finished/Coated Steel Aluminum, Coated Aluminum

Copper

1.1.3. Material Thickness

Steel - .015-in (.38mm) to .027-in (.68mm) Aluminum - .023-in (.57mm) to .040-in (1.02mm) Copper - 16oz (.53mm) to 20oz (.69mm)

1.1.4. Material Strength

STEEL

Maximum Tensile Strength = 48 ksi (330 MPa) Maximum Yield Strength = 33 ksi (230 MPa) (ASTM A611 Grade C or equivalent) ALUMINUM/COPPER

Maximum Tensile Strength = 33-ksi (227-Mpa) Maximum Yield Strength = 28-ksi (193-Mpa)

1.1.5. Strip Width (Stretch-Out)

11 ¾-in (298mm) to 12-in (304mm) [5-in profiles] 15-in (381mm) [6-in profiles]

1.1.6. Profile Dimensions

Refer to the enclosed profile drawings at the end of this Section. All shown dimensions are nominal profile dimensions.

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2. SAFETY FEATURES

2.1. GENERAL SAFETY RULES

Read and understand entire Operator’s Manual prior to use of this machine.

The operator should stay alert and use common sense when operating this and any machine. The operator should not use machine while tired or under the influence of drugs or alcohol.

Proper dress is recommended. Steel toe boots are recommended. No loose clothing or jewelry. Long hair, loose clothing, and gloves should be kept away from all moving parts. Keep the handles dry, clean, and free of oil and grease.

Do not operate without safety glasses and leather gloves. Do not operate without adequate training.

2.2. ELECTRICAL SAFETY

Grounded tools must be plugged into a properly installed and grounded outlet. Never remove the

grounding prong or modify the plug in anyway. Do not use any adapter plugs. Consult with an electrician to ensure that an outlet is properly installed and grounded.

Avoid body contact with grounded surfaces. There is an increased risk of electric shock if ones body is grounded.

Water entering a machine will increase the risk of electric shock. If operating the machine in damp conditions cannot be avoided, use a Ground Fault Circuit Interrupter to supply the power to your machine. Electrician’s rubber gloves and footwear will further enhance operator safety.

Do not abuse electrical cords. Keep the cords away from heat, oil, sharp edges, or moving parts. Do not use damaged cords as they increase the risk of electric shock. Outdoor operation of this machine requires the use of an extension marked “W-A” or ”W”. These cords are rated for outdoor use and reduce electric shock risk.

Do not operate in gaseous or explosive atmosphere.

*DISCONNECT MACHINE FROM POWER SOURCE WHEN NOT IN USE OR WHEN SERVICING *

2.2. MACHINE SPECIFIC SAFETY FEATURES

These machines are designed to roll and form sheet metal. During the rolling process, there is the potential to get ones fingers, hands, toes, and feet pinched between the rollers or other drive mechanisms. Injury could result if one is not careful enough. Use extreme caution at all times when operating this machine. Keep others clear of the area of operation.

If the machine crashes (see Section 11), use extreme caution when clearing the crash. A crash presents a potentially hazardous situation for the machine operator. Crashes often produce sharp, jagged metal edges that ultimately require handling. Suitable hand and eye protection, to include leather gloves and safety glasses, should always be worn when clearing a crash.

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2.2.1. Safety Features

Item Name QTY Part Number Emergency Stop Button 1 ELES-0B63 Top Front Cover 1 0050704 Top Rear Cover 1 0050703 Motor Cover, Top 1 0050702 Motor Cover, Side 1 0050705

Die Cover 1 0052326

Caution Sticker 2 STKR-IBOP

Four safety covers, combined with the design of the machine itself, completely encase the drive

mechanisms of this machine. This prevents both the operator and foreign objects from being introduced into moving machine components.

There is an Emergency Stop button located at the entry end of the machine on the right side. Pressing the E-stop button will cut power and material will stop moving through the machine.

If the CE control package is ordered, the control panel itself has an extra emergency stop button that performs the same function as the entry end button.

*This machine should not be operated without the covers in place. *

Despite the presence of safety features, this machine does have semi-exposed cutting devices.

If the parts the stickers have been placed on need to be reordered for some reason, the stickers will come attached to the parts. Do not use machine without these warning labels.

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3. MACHINE SPECIFICATIONS

3.1. MACHINE SPECIFICATIONS – MECHANICAL SYSTEMS 3.1.1. Basic Machine Specifications

Length = 136-1/2-in (3467mm) (with Rack Shear) Width = 26-in (660mm)

Height = 24-in (610mm)

* Weight (base machine) = 1685-lbs (766-kg) Height (Including Uprights) = 35-in (889mm) Height (Including Spool) = 51-in (1295mm)

*Note: Refer to the data sheet at the end of this Section for all weight specifications.

3.1.2. Roll-forming Details

8 powered roll-forming stations

5-station auxiliary box unit (5-in profiles) 4-station auxiliary box unit (6-in profiles)

3.1.3. Production Speed

+50 ft/min (+15 m/min) nominal production speed (60 Hz Electric Motor @ 1725 rpm) +41 ft/min (12.5 m/min) nominal production speed (50 Hz Electric Motor @ 1425 rpm)

3.1.4. Drive Train

Power Source - Electric Motor

Power Take off - Synchronous Gear Belt Drive

Drive/Forming Rollers - Gear/Sprocket/Roller Chain Drive

Main Drive Speed – 65 rpm @ Ø3.00 Drive Diameter (60 Hz Electric Motor @ 1725 rpm) Main Drive Speed – 54 rpm @ Ø3.00 Drive Diameter (50 Hz Electric Motor @ 1425 rpm)

3.1.5. Shear Assembly (Cut-off Shear)

5-in Manually Operated Rack and Pinion Guillotine Shear (Rack Shear) (KR-50A, KR-56A) 6-in Manually Operated Rack and Pinion Guillotine Shear (Rack Shear) (KR-60A, KR-56A) 5-in Circular Cam Shear Assembly (KR-50A, KR-56A)(Optional)

6-in Circular Cam Shear Assembly (KR-60A, KR-56A)(Optional)

3.1.6. Coil Handling Equipment

Double Uprights

Single Combination Spool (16-in I.D.) 16-in ID Combo Spool (Optional) Triple Uprights (Optional) 6-in Coil Cradle (Optional) 5-in Coil Cradle (Optional) Double Cradle Uprights (Optional)

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3.1.7. Airborne Noise Emissions

Equivalent continuous A-weighted sound pressure level = less than 70 dB (A)

3.2. STANDARD MACHINE SPECIFICATIONS – ELECTRICAL/CONTROL SYSTEMS 3.2.1. Electrical Power System

3.2.1.1. Standard Package

- Line Voltage = 100-115 Volts AC / 200-230 Volts AC (+/- 10%) - Line Current = 15 Amps

- Line Frequency = 60 / 50 Hz (+/- 1%) - Line Phase = 1φ (single phase)

- Full Load Current = 12.6-14.2 Amps / 6.3-7.1 Amps - Fuse Rating = N/A

- Electrical Drawing = 005-00-02 - Electrical Enclosure IP Rating = N/A

3.2.1.2. CE Certification Package (KR-50A, KR-60A, KR-56A) (Optional)

- Line Voltage = 100-115 Volts AC / 200-230 Volts AC (+/- 10%) - Line Current = 15 Amps

- Line Frequency = 60 / 50 Hz (+/- 1%) - Line Phase = 1φ (single phase)

- Full Load Current = 12.6-14.2 Amps / 6.3-7.1 Amps - Fuse Rating = 5 Amps

- Electrical Drawing = 005-00-01 - Electrical Enclosure IP Rating = IP4X

3.2.2. Control System

Directional Control/Electric Motor Control: Three- (3) position drum switch (red handle)

Direction Selector Switch, Jog/Stop/Run Switch, Jog Push Button, E-Stop Switch (Optional CE Package)

3.2.3. Safety Features

E-Stop Switch Top and Side Covers Spool Locks

Additional E-Stop Switch (part of optional CE Package control panel)

3.3. MACHINE SPECIFICATIONS – OPERATING ENVIRONMENT

The machine will operate correctly under the following environmental conditions:

3.3.1. Ambient Air Temperature Range

+41 to +131°F (+5 to +55°C) Up to 24 hours at 122°F (50°C)

3.3.2. Humidity Range

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3.3.3. Altitude Range

Up to 10,000 feet (3,000 meters)

3.3.4. Vibration, Shock, and Bump

The machine will perform correctly under conditions normally associated with vehicular transport on maintained roads. Off-road transportation (to include non-maintained roads) may result in incorrect machine operation.

3.3.5. Transportation and Storage

-13 to +131°F (-25 to +55°C) Up to 24 hours at +158°F (+70°)

3.3.6. Explosive Atmosphere

The KR-Series Gutter Forming Machine is not designed for use in any type of explosive atmosphere. The

machine should not be operated in an explosive atmosphere of any kind. 3.4. OPTIONAL MACHINE ACCESSORIES

Run-out Stands

Free Float Hook Assembly 1-in Flange Assembly 2-in Flange Assembly

Footage Counter (Imperial or Metric Units)

3.5. INTENDED USE

The KR-SERIES Gutter Forming Machines are intended to form the aforementioned specific profiles from the designated material specifications. The machines are in no way intended for any other purpose. Any attempt to use the machines for different purposes may result in serious personal injury or significant damage to the machines. In particular, the machines are not intended to form partial or different profiles; not intended to run unspecified material thicknesses or widths, not intended for use as straightening or flattening devices; not intended for use as any sort of winding, coiling, or uncoiling mechanisms.

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Data Sheet

MACHINE/ACCESSORY WEIGHT SPECIFICATIONS

Item Weight (lbs) Weight (kg)

Base Machine 1685-lbs 766-kg Machine Entry End Cover 7-lbs 3.2-kg Machine Exit End Cover 18-lbs 12.7-kg Machine Motor Cover 15-lbs 6.8-kg 5-in Rack and Pinion Shear 29-lbs 13.2-kg 6-in Rack and Pinion Shear 40-lbs 18.2-kg 5-in Cam Shear 28-lbs 12.7-kg 6-in Cam Shear 28-lbs 12.7-kg 5-in Skate Roller (back) 6-lbs 2.7-kg 6-in Skate Roller (back) 9-lbs 4.1-kg 5-in Box Unit 25-lbs 11.4-kg 6-in Box Unit 48-lbs 21.8-kg Free Float Hook Assembly 18-lbs 8.2-kg 1-in Flange Assembly 21-lbs 9.5-kg 2-in Flange Assembly 23-lbs 10.5-kg Bead Attachment Unit 20-lbs 9.1-kg 16-in ID Combo Spool 75-lbs 34.1-kg 20-in ID Combo Spool 100-lbs 45.5-kg Double Uprights 45-lbs (each side) 20.5-kg Triple Uprights 60-lbs (each side) 27.3-kg 5-in Coil Cradle 50-lbs 22.7-kg 6-in Coil Cradle 60-lbs 27.3-kg Double Cradle Uprights 85-lbs 38.6-kg Tool Box (empty) 33-lbs 15.0-kg Tool Box (full) 110-lbs 50.0-kg Run-out Stands 15-lbs 6.8-kg

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4. TERMINOLOGY

4.1. MACHINE NOMENCLATURE

Entry end - the end of the machine into which the material is fed, the end with the black curved guides;

also called the front end or feed end

Exit end - the end of the machine from which the finished gutter profile emerges, the end with the shear;

also called the rear end or discharge end

Forming rolls - the rotating contoured dies used to both drive the material through the machine and form

the finished gutter profile; also called forming dies, rolling dies, rollers

Left side - when viewing from the entry end of the machine, the side located to the left

Right side - when viewing from the entry end of the machine, the side located to the right. Also called the

“Box Side.”

Station # - forming stations are numbered sequentially from the entry end to the exit end of the machine Crash – a condition in which any of the following problems may exist:

• metal will not move through the machine

• metal is bent or crumpled against a fixed component in the machine • metal is bunching up between forming stations

• the drive train is seized

4.2. PROFILE SPECIFIC TERMS

The profile is normally described as if it were being viewed from the entry end of the machine as the material runs:

Away from the house - profile is horizontally level, but curves toward the front, or box side, of the gutter Into the house - profile is horizontally level, but curves toward the back side of the gutter

Downhill - the profile runs laterally strait, but curves downward as it exits the machine; also referred to as

having a crown in the profile

Uphill - the profile runs laterally strait, but curves upward as it exits the machine Left - the profile is horizontally level, but curves to the left as it exits the machine Right - the profile is horizontally level, but curves to the right as it exits the machine Twist - one end of the profile rotates away from the other end

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Camber - lateral curvature in coil stock - camber may lead to an inconsistent profile

Coil Set - longitudinal curvature induced in coil stock due to the winding or coiling process - excessive coil

set may cause rippling in the gutter profile

Edge wave - a ripple-like effect on the edge of the material - often caused by the slitting process

Gauge - term used to reference the thickness of steel material per AISI thickness tolerance ranges - ex: 24

Ga = .0276" thick

Long-centered - center of the coil stock strip slightly longer than the edges - often results from the

annealing process

Oil canning - a periodic pattern of buckling appearing on flat sections of a profile - often results from coil

set

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5. REQUIRED TOOLS AND EQUIPMENT

5.1. HAND TOOLS

5.1.1. Combination or Open End Wrenches

½-in, 9/16-in, ¾-in, 15/16-in, 1-1/8-in

5.1.2. T-Handle Hex Wrenches

5/32-in, 3/16-in, 7/32-in, ¼-in, 5/16-in, 3/8-in

5.1.3. L-Handle Hex Wrenches

5/32-in, 3/16-in, ¼-in, 5/16-in

(Ball Nose L-Handle Hex Wrenches Recommended)

5.1.4. Tin Snips

Right Hand, Strait, or Left Hand Snips (All Three Recommended)

5.1.5. Feeler Gauge

5.2. ELECTRICAL EQUIPMENT

5.2.1. Electrical Generator/Power Source

4500 Watt (4.5 kW) minimum

5.2.2. Extension Cord

#12 AWG 3-wire extension cord with grounded connector - maximum length 100 feet.

5.3. LIFTING EQUIPMENT 5.3.1. Mounting the Machine

The basic machine weighs approximately 1685-lbs (766 kg). The Manufacturer recommends using a lift with a safe operating capacity of at least 2000-lbs (900-kg) when mounting or moving the machine. Lifting equipment may include forklifts, overhead cranes, or cherry pickers. Remove all coils/spools prior to any lifting or moving operation. Coils/spools should be lifted separately.

5.3.2. Loading Spooled Coil

The maximum recommended coil size for any one set of spool uprights or cradle is 500-lbs. Lifting equipment for loading spooled coil should be able to easily handle 1.25 times the maximum coil size for reliability and safety.

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6. INSTALLATION

6.1. RECEIPT/UNPACKING

Check the contents of the shipment and compare them to the shipping package list. Check for any missing or damaged components. Some parts/sub-assemblies may be shipped inside the machine, and must be removed prior to any operation. Contact your Knudson Mfg., Inc. Distributor if any problems exist.

6.1.1. Lifting, Moving, and Placement

Follow all safety guidelines when conducting any lifting operations. Failure to follow safety rules could result in serious personal injury.

Never attempt to lift, move, or place the machine with spooled coil on the uprights, or coil loaded in top mounted cradles. All installation should be completed without coil stock present/loaded.

The KR-56A is shipped from the factory on 4x4 skids, or on a crate bottom. The skids and/or crate bottom are normally discarded, and the machine is mounted on new 4x4’s or directly to a mounting surface. To remove the skids/crate, the entry end of the machine may be lifted by the uprights to expose the machine’s base.

In order to lift and place the machine, the KR-56A should be lifted from the underside of the frame. Because the machine’s weight is centered near the entry end, the machine does not balance and should not be lifted in its entirety by the uprights.

When using a forklift and lifting from the side of the machine, the forklift should be centered near the exit end of the top motor cover

When using a forklift and lifting from either end of the machine, fork extensions should be used to reach as far as possible under the frame, and a safety chain should be wrapped around the machine and the forks to prevent any tipping.

If a forklift will be used to push the machine, be sure the forks push against a frame member or a frame base rail. Do not push directly against the exit end plate or the side plates.

Again, due to balance problems, the KR-56A is not normally lifted and placed via the uprights.

6.2. MOUNTING INSTRUCTIONS 6.2.1. General

READ ALL MOUNTING INSTRUCTION PRIOR TO MOUNTING THE MACHINE. The gutter

machine should be permanently mounted where it will be used (in the bed of a pickup or panel truck, on a trailer, on a special bench). The machine should be used only in a level position with the rear or discharge end of the machine aligned toward the rear of the truck.

***WARNING*** NEVER cinch the machine down to match the contour of a truck bed, trailer, or bench.

Wherever the machine frame does not meet the mounting surface, use shims of wood, metal or other suitable material to achieve a solid four-point mount. Forcing the machine frame to twist or warp to conform to an irregular surface will result in serious loss of critical pressure adjustment between roller sections in the machine. The machine’s chassis is very rigid, and shims should be used to retain the original shape of the machine frame when mounting.

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Note: In many cases, even a new truck may have as much as 2-in (50-mm) of twist in an eight-foot bed.

6.2.2. Location of Controls

In order to comply with European Union Machinery Directive (98/37/EC), the controls (electrical

enclosure) must be located between 20-in (.5-m) and 75-in (1.9-m) above the surface on which the operator will stand while operating the machine. Surfaces may include the ground, a truck bed, or a trailer deck.

6.2.3. Truck or Trailer Mounting

Find the six holes in the frame angle mounts, located along the bottom edges on the sides of the machine. See Figure 5.1. The frame angle mounts have 3/8-in holes for mounting the machine directly to the bed of the mobile unit. Cut a pair of 24-in long 2X4's or 4X4's to fit horizontally across the bed of the vehicle. These will provide some clearance under the machine and act as road vibration absorbing pads. Six (6) 3/8-in bolts of sufficient length should be used to secure the mach3/8-ine to the vehicle bed. Rubber padd3/8-ing may be used for added insurance against road vibration and possible loosening of machine adjustments.

NOTE: Allow at least 8-in (200-mm) of clearance between the front wall of the vehicle (as in a pickup or

flatbed) and the front spool of the machine. This creates the proper clearance for feeding material off the spool into the machine. This clearance is also necessary for occasional slacking of material as the spool pays out.

Figure 6.1: Holes for truck or trailer mounting.

6.2.4. Shop or Other Stationary Mounting

3/8-in mounting holes (similar on other side)

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READ THE TRUCK OR TRAILER MOUNTING INSTRUCTIONS AS WELL AS THIS SECTION BEFORE STATIONARY MOUNTING OF YOUR MACHINE. For stationary mounting, ensure the

table, bench, rack or horses are solid and level. For both safety and stability, securely bolt the machine to the mounting arrangement. Again, ensure the frame is not cinched down to an irregular base, but rather shimmed to make solid contact at four points. Support in the center of the machine is recommended but not required. The first step toward production of high-quality gutter is a level, properly mounted machine. Prior to mounting the machine, consider how the coil stock will be fed into the machine. Metal should be fed into the machine in a downward direction from the payoff reel mount atop the machine. Floor mounted reels or mobile units can be extremely difficult to align with the machine, and they typically produce acceptable results only when securely fastened to the machine. Rippled gutter may result if the coil stock is not fed into the guides at a downward angle.

Contact the factory for further information on specific mounting situations. Information is readily available upon request, free of change, from the factory.

6.3. INITIAL INSPECTION

INSPECT THE MACHINE BEFORE OPERATING

UNPLUG THE MACHINE BEFORE REMOVING THE SAFETY COVERS

During transport, parts of any machine may vibrate loose and/or foreign objects may accidentally be directed into the machine.

The operator must remove the safety covers and carefully examine the entire machine before operation. Ensure that:

• no foreign objects are present which could cause damage to machine parts • all fasteners are tight and in proper position

• drive-train components are lubricated, properly adjusted and ready for operation • coil stock in machine is clean, free of foreign objects and unobstructed.

REPLACE THE SAFETY COVERS PRIOR TO OPERATION

After adjustment or repair, be sure all tools are removed from machinery prior to operation.

6.4. WIRING INSTRUCTIONS

FAILURE TO COMPLY WITH THESE PROVISIONS WILL RESULT IN MOTOR DAMAGE 6.4.1. Power Source

The standard gutter machine is normally wired for 115 Volt AC or 230 Volt AC, single phase (1φ), and fifty or sixty cycle (50/60 Hz). To switch between 115 VAC and 230 VAC, use the toggle switch located on the electric motor. Be sure the machine is unplugged before switching the electric motor line voltage toggle switch. After switching, fix the switch in place with an electric wire tie or other suitable device. Wiring connections may be verified in accordance with the electrical diagram.

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6.4.2. Electric Generators

The electric motor draws about 4000 Watts when staring and can be driven by a 4500-Watt generator.

DO NOT TRY RUNNING THE MACHINE ON A SMALLER GENERATOR! Damage to both the

generator and motor will result. The manufacturer will not be held responsible for such damage.

6.4.3. Extension Cords

Use extension cords with at least #12 wire and no longer than 100 feet. Longer extension cords will cause excessive power drops, capable of damaging motor windings unless extremely heavy wire is used. Be sure to use 3-wire extension cords with grounded conductors. Failure to use the correct size extension cords could create a serious shock hazard. TAKE NO CHANCES ON THIS. If in doubt about the wire size in an extension cord, use a larger size.

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7. SETUP AND OPERATION

• Note: determine what type of control package is installed on the machine. All operators should familiarize themselves with the appropriate controls prior to any operation.

7.1. MACHINE CONTROLS – STANDARD

The Standard Control package includes a red drum switch (motor control) located on the exit end plate on the right side, and an E-Stop switch located on the right side near the entry end.

Figure 7.1: View of standard wiring package. Covers and internal mechanisms are not shown for clarity.

The Motor Control drum switch has three positions for electric motor control:

Switch Position Action

Up Forward Middle Off

Down Reverse

The switch will remain in whatever position it is placed (maintained switch), and will therefore support continuous operation in both the forward and reverse directions.

Pushing the E-Stop switch will disconnect input power.

7.2. MACHINE CONTROLS – CE WIRING PACKAGE

E-stop Button

Red Drum Switch (motor control)

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The CE Certified control package includes a control box mounted on the right side near the exit end, and an E-Stop switch located on the right side near the entry end.

Figure 7.2: View of CE control package. Covers and internal mechanisms are not shown for clarity. The control box features four switches with the following functions:

E-Stop Switch (Red Mushroom Push Button):

Switch Position Action

Pulled/Out On (power) Pushed/In Off (power)

Once pushed in, the E-Stop Switch key must be turned to pull the switch out and restore power. Because the Advance button must be pushed to initiate and action, pulling the E-Stop out and restoring power alone will not initiate any machine action.

Direction Selector Switch (Black Two-Position Switch):

Switch Position Direction

AV Forward ARR Reverse

This switch determines which direction the machine will run when the Advance Button is pushed. It will initiate no action by itself

Mode Switch (Black Three-Position Switch):

E-stop Button E-top Button Advance Button Direction Selector Mode Switch

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Switch Position Mode

CPC Jog O Off NORMAL Continuous Operation

The mode switch will determine what will happen when the Advance Button is pushed. In the Jog Mode, the machine will only advance (forward or reverse) if the Advance Button is held down. In the Off Mode, the machine will not run. In the Continuous Operation Mode, the machine will start when the Advance Button is pushed, and will continue to run after the Advance Button is released.

Switch the Mode Switch to OFF to Stop the machine or discontinue continuous operation!

Advance (ENCLENCH) Button (Black Spring-Return Push Button): Switch Position Action

Pushed On Released Off (Jog Mode) or On

(Continuous Operation Mode)

Push the Advance Button to Jog the machine (forward or reverse) or initiate continuous operation (forward or reverse). The resulting action will depend on the position of both the Mode Switch and the Direction Selector Switch.

Switch the Mode Switch to OFF to Stop the machine or discontinue continuous operation!

7.3. ELECTRICAL VERIFICATION – STANDARD WIRING PACKAGE 7.3.1. Initial Power-Up

*** OBSERVE ALL SAFETY RULES WHEN WORKING WITH ELECTRICITY ***

Inspect all wiring, connections, and electrical components prior to plugging in the machine. Ensure the Motor Control drum switch is in the OFF (middle) position. Plug the machine in, then re-inspect. Look for any unusual conditions (broken or burnt wires, smoke, or unusual noise). Immediately unplug the machine if any unusual conditions exist.

7.3.2. Correct Motor Rotation

First, ensure the E-Stop switch is pulled out. Briefly bump the motor control switch into the Forward position then back to the Off position. Observe the direction the forming rollers rotate. Verify the rollers will drive material from the entry end to the exit end when the Motor Control drum switch is in the Forward position.

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Verify the E-Stop Switch functions correctly by first pushing the E-Stop Switch. Attempt to jog the machine forward with the Motor Control drum switch. With the E-Stop switch pushed in, the motor should have no power supply and should not work. Now, place the Motor Control drum switch in the Off position.

*** CAUTION - IF THE MOTOR CONTROL DRUM SWITCH IS SET TO FORWARD OR REVERSE AND THE E-STOP IS PULLED OUT, THE MOTOR WILL START TURNING***

Pull the E-Stop out to restore power to the motor and resume normal operation.

7.3.4. Electrical Receptacle

Verify operation of the receptacle using a multi-meter, a light, or a piece of portable electrical equipment like a power tool. If power tools are used to test the receptacle, ensure the tool is rated for the same voltage as the machine’s power source. In addition, if the optional safety circuit is installed, the receptacle will be a Ground Fault Interrupt type receptacle.

7.3.5. Wiring Diagrams

If the motor, receptacle, or E-Stop switch do not function correctly, contact the factory and request wiring diagrams. The diagrams may be used to troubleshoot the circuitry. Do not attempt to troubleshoot electrical problems if you are not familiar and comfortable with basic wiring practices and procedures.

7.4. ELECTRICAL VERIFICATION – CE CERTIFICATION PACKAGE 7.4.1. Initial Power-Up

*** OBSERVE ALL SAFETY RULES WHEN WORKING WITH ELECTRICITY ***

Inspect all wiring, connections, and electrical components prior to plugging in the machine. Ensure the Mode Switch is in the Off (O) position. Plug the machine in, then re-inspect. Look for any unusual conditions (broken or burnt wires, smoke, or unusual noise). Immediately unplug the machine if any unusual conditions exist.

7.4.2. Correct Motor Rotation

First, ensure both E-Stop switches are pulled out, and ensure the Direction Selector switch is in the Forward position. Place the Mode switch in the Jog position (CPC). Briefly press the Advance Button, and observe the direction the forming rollers rotate. Verify the rollers will drive material from the entry end to the exit end when the Advance Button is pushed in.

7.4.3. Emergency Stop Switch (E-Stop)

Verify the E-Stop Switches function correctly by first pushing in one of the E-Stop Switches. Attempt to jog the machine forward with the Advance button. With the E-Stop switch pushed in, the motor should have no power supply and should not work. Pull the E-Stop switch out. Again, attempt to jog the machine forward. The machine should now operate normally.

Test both E-Stop switches in this manner.

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Verify operation of the receptacle using a multi-meter, a light, or a piece of portable electrical equipment like a power tool. If power tools are used to test the receptacle, ensure the tool is rated for the same voltage as the machine’s power source.

7.4.5. Wiring Diagrams

If the motor, receptacle, or E-Stop switch do not function correctly, contact the factory and request wiring diagrams. The diagrams may be used to troubleshoot the circuitry. Do not attempt to troubleshoot electrical problems if you are not familiar and comfortable with basic wiring practices and procedures.

7.5. CLEARING THE MACHINE

Once correct motor rotation has been established and the electrical verification procedures have been performed, run the material in the machine out the exit end. If incorrect motor rotation or the electrical verification procedure backed the gutter profile out of the shear, follow the procedures in section 9 for re-threading the shear.

7.6. DRIVE TRAIN VERIFICATION

After the machine has been cleared, place the Run/Sop switch in the Run position for continuous operation. Inspect the gears, sprockets, roller chain, and gear belt drive for smooth, quiet, unobstructed operation. The drive train should be adequately lubricated from factory testing. Inspect for proper lubrication and lubricate as necessary.

7.7. INITIAL SETUP

The machine has been completely set-up, tested, and adjusted at the factory for the coil stock specified upon ordering. The gutter machine should produce acceptable gutter using the specified coil stock with only minor or no adjustments.

7.7.1. Initial Setup Inspection

A rapid visual inspection may be performed prior to threading the machine. Check the following items: • Top/bottom alignment of Station #1, #2, and #3 forming rollers

• Metal clearance between forming rollers throughout the machine • All rollers in the box assembly are aligned and turn freely • Clearance between box rollers is set at .047-in (1.19mm) • Skate Bar/Station #3 top roller alignment

7.8. LOADING COIL 7.8.1. Coil Requirements

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Use 16-in (406-mm) or 20-in (508-mm) ID coil stock for easy placement on the appropriate spool.

7.8.2. Loading Coil Stock onto the Spool

Loosen the ½-13 hex head bolts in the spool flange and slip it off the center pipe. With the coil standing upright, slip the spool through the coil, attach the flange snug against the coil stock and tighten the ½-13 hex head bolts.

7.8.3. Loading the Spooled Coil onto the Machine

Insert the ∅1" x 24" long solid bar shaft into the spool center pipe. Lifting from the solid bar shaft exposed on both ends of the spool center pipe, use a chain hoist, lift truck, or a ramp to lift the spooled coil into place on the uprights or cradles. Once the spooled coil is resting in place on the uprights or cradles, the spool/coil should be secured in place with upright spool locks or with a cradle center bar.

7.9. THREADING THE MACHINE WITH COIL STOCK

Keep all tools, fittings, hardware, debris or other material away from the feed end of the machine. The coil stock feeding into the roller sections will act as a conveyor for such foreign items. Extremely serious damage to the rollers will occur should any foreign objects be carried through the machine in such a fashion. Gutter spikes, nails, wrenches, and rivets are typical violators of this rule. Your warranty does not cover such accidents. Irreparable damage can occur to both sets of rollers. Be extremely careful in this matter.

The coil stock should top feed off the spool to avoid forming rippled gutter. Spool stops in the spool mounts should be used to lock the coil during transportation. Loosen these stops before trying to use the machine.

7.9.1. Cutting a Leading Edge on the Coil Stock

For easy threading, clip the corners of the leading edge of the coil as shown in Figure 7.3.

Figure 7.3: Clip the corners of the leading edge for easy coil threading.

7.9.2. Entry Guides

3 in (75 mm)

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Feed the trimmed leading edge around the front feed roller and between the entry guide plates. Be sure the metal is directed between the first set of top and bottom rollers and is centered between the vertical bars of the entry guide plates. Allow slack for the rollers to grab the leading edge of the metal. A strong push is usually required to start the coil into the first pair of rollers after the guides.

The entry guides may require a width adjustment prior to attempting to thread the machine. Standing at the front of the machine and facing the feed rollers, the left side of the machine is to your left. If necessary, adjust the width between entry guides by moving the Left Entry guide. Use the left-hand inside 3/8-in socket head screws (5/16-in hex wrench) to set the width. Leave about 1/32-in clearance between the coil stock and each guide, but no more than 1/32-in (.79mm).

Figure 7.4: Top view of entry end of machine.

7.9.3. Threading the Machine

Place the motor control switch in the forward position and verify the rollers are turning in the proper direction. Push the leading edge of the metal into the forming rollers. From the front end of the machine, watch the first two (2) or three (3) feet feed in, then stop the machine. Verify the leading edge feeds smoothly, free from any obstructions. The power may be disconnected and the top safety covers removed to inspect the feed process. Feed the leading edge up to the shear, then stop the machine. Again, be sure the leading edge feeds smoothly, free from any obstructions.

7.10. THREADING THE CUT-OFF ASSEMBLY (SHEAR) 7.10.1. Threading the Cut-off Assembly (Shear)

If you are threading the machine with the cut-off assembly attached, stop the machine with the profile just short of the cut-off dies. Jog the leading edge up to the dies. Ensure the blade is clear of the die openings, and that no obstructions exist. Carefully advance the metal through the cut-off die openings until

approximately 1-in (25mm) extends beyond the cut-off dies.

7.10.2. When to Perform the Threading Procedure

Entry guide width adjustment screws

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This procedure need be done only on each new coil or after removing the cut-off assembly from the machine for any reason. With metal in the machine and adjustments correctly set, the gutter will feed automatically through the cut-off assembly when the motor control switch is operated.

7.11. CUT-OFF ASSEMBLY (SHEAR) OPERATION 7.11.1. Operating the Rack Shear

To operate the Rack and Pinion Shear, slip the cheater bar over the adapter bar on the shear assembly drive shaft. The adapter bar may be bolted to either end of the drive shaft. Rotate the shear handle toward the exit end of the machine 190 degrees. Return the bar to its original position to complete the shear cycle.

7.11.2. Operating the Optional Circular Cam Shear

To operate the optional Circular Cam Shear, first press in the mechanical release bolt located at the top center of the assembly. Rotate the shear handle clockwise (facing the exit end) three revolutions to complete a shear cycle. At completion, the mechanical stop will re-engage.

Figure 7.5: Diagram of the optional cam shear.

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7.12. RUN-OUT STANDS 7.12.1. Setting Up Run-out Stands

Gutter run-out stands must be used when forming gutter in lengths over ten (10) feet (3 meters). The stands (or table) must be level and in line with the machine rollers. Knudson Mfg., Inc. adjustable gutter stands are recommended and are available from the factory. Run-out tables are good for shop use if they have an adequate number of rollers or a non-scratching surface.

7.12.2. Effect on Gutter Profile

If the gutter curves upward, the run-out stands may be set too high. If downward, the stands may be set too low. If the gutter curves to either side, the machine may be tilted in that direction and should be leveled.

7.13. LENGTH MEASUREMENTS 7.13.1. Measuring Gutter Lengths

A tape holder attached to the end plate (exit-end) of the machine is built for a 100-ft (30-m) standard steel tape measure. Place a tape in the holder and hook the tape end on the leading edge of the gutter. The tape pays out as gutter rolls out of the machine. Watch the reading on the tape as you run the machine. Use the inside edge of the outside cutter blade as a mark to determine the exact gutter length prior to operating the cutter.

Figure 7.6: Tape holder.

The optional Footage Counter may also be used as a reference to determine part length. Both Imperial and Metric counters are available. The counter functions as a totalizer, measuring the accumulated length of material run through the machine. Part length may be determined by comparing the difference between start and finish values on the counter.

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8. ADJUSTMENT AND TROUBLESHOOTING

ENSURE ALL SETUP AND OPERATING PROCEDURES IDENTIFIED IN SECTIONS 7 AND 9 HAVE BEEN FOLLOWED AND VERIFIED PRIOR TO ADJUSTING THE MACHINE

READ ALL SECTION 8 ADJUSTMENT PROCEDURES BEFORE ADJUSTING THE MACHINE UNPLUG ALL POWER SOURCES BEFORE REMOVING THE SAFETY COVERS

8.1. THREADING

Review section 7. Ensure all parts installed match the desired profile width. (Ex: blue parts for 5-in gutter). Also, verify that the coil’s leading edge has been cut in accordance with these instructions. Using an inspection mirror, check for obstructions as the coil stock material is jogged through the machine.

8.2. SHEARING

Review section 7. With no material in the cut-off assembly, check for free rotation of the gears and crank and unobstructed travel of the cutter blade. If the cut-off assembly leaves burrs, or cuts poorly with a great deal of effort, visually inspect the blade and dies for sharp edges, and ensure all fasteners are properly tightened.

8.3. PROFILE CURVATURE ADJUSTMENTS

If the machine forms curved gutter and the run-out stands are properly set; the machine requires further adjustment. Read all adjustment procedures before making any adjustments. If adjustments are required, always try the “A” adjustment first. Use "B" adjustment only if/after the "A" adjustment fails to produce the desired result. After making each adjustment, cut the gutter off, if possible, then run out five or six feet and sight down the respective bottom corner in question. Upper extremities of the gutter will either follow the bottom or pose no problem once the bottom is straight. Do not try to achieve absolute perfection in adjusting your machine. Curvature of ¼-in in 10-ft (6mm in 3m) can be over-ridden by proper placement of run-out stands.

The machine leaves the factory in "basic adjustment" plus proper adjustment for at least one gauge of material. Variations of as much as .005-in (.13-mm) over or under standard .027-in (.68-mm) thick aluminum or one gauge over or under 26Ga (.55-mm) galvanized steel will have only minor effects on the performance of the machine and generally will not require special adjustments.

8.3.1. First Things to Check in the Machine

In the event of curvature, the following items should be checked: • Top/bottom alignment of Station #1, #2, and #3 forming rollers • Metal clearance between forming rollers throughout the machine • All rollers in the box assembly are aligned and turn freely • Clearance between box rollers is set at .047-in (1.19mm)

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D Station 1 Station 8 Station 7 Station 6 Station 5 Station 4 Station 3 Station 2

Left Side Exit End Right Side

Direction of Material Flow C B A C B A Box adjustment screws A B C Exit end of box Entry end of box

Figure 8.1: Layout of adjustment screws.

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Adjustment Procedures REFER TO FIGURE 8.1

TYPE OF CURVATURE CORRESPONDING ADJUSTMENTS

1. Gutter curving to right, but relatively level. (1A) Loosen A and C of the right side of station 8 1/4 turn; tighten B 1/4 turn; check results and repeat as necessary

(1B) Loosen A and C of the right side of station 7 ¼ turn and tighten B ¼ turn. This may help amplify adjustment in (1A) above

2. Gutter curing to left, but relatively level. (2A) Loosen B of the right side of station 7 1/4 turn; tighten A and C 1/4 turn.

(2B) Loosen B of the right side of station 8 1/4 turn; tighten A and C 1/4 turn to amplify effect of (2A) if necessary.

NOTE: At this point, the objective is to use pressures on the right side of stations 7 and 8 to force the

material to curve in the opposite direction. Some side effects such as twisting may show up here, but they will be dealt with in subsequent instructions. The important result must be gutter that is running in a straight line without regard for up & down curvature or twist.

3. Gutter curving downward on right (face or front) side.

(3A) Loosen A & C on the exit end of the box ½ turn & tighten B ½ turn. Check results & repeat as necessary.

(3B) Loosen B of the entry end of the box ½ turn and also loosen D ½ turn, bringing box assembly toward side of machine. Re-tighten B into place.

4. Gutter curving upward on right (face) side. (4A) Loosen B of the exit end of the box ½ turn and tighten A and C ½ turn. Repeat if necessary. (4B) Loosen B of the entry end of the box ½ turn and D ½ turn pushing box assembly toward inside of machine, and re-tighten B into place.

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Figure 8.2: Crimper assembly.

5. Gutter curving downward on back (crimp) side. (5A) Tighten crimper adjustment screw B 1/4 turn to

deepen crimp. This will help pull gutter up on backside. Check results and repeat as necessary. Extreme adjustment here will result in ripples in back of gutter.

6. Gutter curving upward on back (crimp) side. (6A) Loosen crimper adjustment screw B 1/4 turn to allow more clearance between crimper gears. You may have to tap the threaded 5/8" shaft of the inside here to force it to release. Repeat if necessary, but remember that too little crimp may allow back of gutter to wave or ripple.

Using pressure on the right side of stations 7 and 8 in conjunction with proper box elevation and crimp will produce straight gutters from practically any standard material available. It is a balance of these

adjustments that allows a machine to perform properly.

8.4. PROFILE TWISTING ADJUSTMENTS

Twisting of gutter results from one or both sides of the bottom of the gutter curving away from level. If one side of the gutter is level or straight, while the other side curves up or down, twist results. One side may curve up while the other curves down, also resulting in a twist.

8.4.1. Adjustment Procedures

Cut off five or six feet of twisted gutter and sight down each bottom corner. Make adjustments only on the side that curves up or down. Refer to adjustments 3-6 above for instruction on correcting such curvature. Once the gutter is running fairly straight but still exhibiting a slight twist, a slight increase of pressure using adjustments on the right of stations 7 and 8 will correct the situation. Remember to loosen the stand-off screws A and C and tighten the pressure screw B on right side only to correct the twist. Adjustments of as little as 1/8 - 1/4 turn will show noticeable change within 3 to 4 feet (1 to 1-1/2 meters) of gutter produced.

Crimper adjustment screw A Crimper adjustment screw B

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You need work with only the last cross bar adjustments (stations 7 and 8) to correct most twisting. In extreme cases, it may be necessary to use box elevation or lowering or a change of crimp to level the gutter.

8.5. FRONT TOP EDGE OF GUTTER ADJUSTMENTS 8.5.1. Curvature

Typically the top of the face side of the gutter curves outward slightly, especially at the tail end of the gutter formed. Adjustment of the screw shown in figure 7.3 will help compensate for such curvature. Tightening this adjustment in 1/4-turn increments with observation of 3 to 4 feet (1 to 1-1/2 meters) of formed gutter will alleviate such a problem. Conversely, loosening the adjustment screw will compensate for inward curvature of the top front edge. Extreme adjustment here (3 or 4 turns) may have an adverse effect.

Figure 8.3: Close up of box top edge adjustment screw.

Be sure the box unit is roughly parallel with the side of the machine. This will eliminate the tail on the top edge of the gutter.

8.5.2. Width of Return

The width of the returned top edge of the gutter should measure between 9/16 and 5/8-in (14.3 and 15.9-mm) wide. Lowering both ends of the box unit without moving it in or out will add a like amount of width to the return edge and vice versa for shortening the width. Moving the entire box unit (both ends) inward will also add to this top edge width. The amount of hem may vary slightly with this procedure.

Top edge curvature adjustment screw.

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8.6. WIDTH OF GUTTER ADJUSTMENTS

Different materials and different gauges of the same material will cause a machine to produce gutter of varying widths. Several remedies are available for over wide gutters.

8.6.1. Right Angle (90 degrees) - Backside to Bottom

Check the angle formed between the backside and bottom of the gutter. This angle should be close to 90°. Correct for over bending (+90º) as follows:

• Ensure the gap between the side roller on left side #8 and the last left side skate roller (above bottom roller #8) is approximately metal thickness plus a few thousandths of an inch. Adjust this gap using the set-screw identified in figure 8.4. Lock the 3/8-in bolts securely when satisfied.

• Angle the crimper assembly so that the top crimped edge of the backside of the gutter is pulled in slightly. This is properly set at the factory and should be adjusted only as a last resort.

Figure 8.4: Rollers used to adjust angle between back side and bottom of gutter. Left side roller

number 8 Last left side skate roller

Adjustment set screw

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8.6.2. Box Unit Position

Moving the exit end of the box unit (see figure8.1) inward will help narrow the gutter.

8.7. ADJUSTMENT FOR WIDTH OF COIL STOCK/IMPROPER HEMMING

The machine will be factory-adjusted to form the proper hem on the top front inside edge of the gutter. Therefore DO NOT change the position of the right entry guide should the machine fail to hem properly. Instead, follow this procedure:

8.7.1. Adjustment Procedures

Cut off a short piece of coil stock and insert it between the entry guides. Adjust the position of left entry guide by adjusting entry guide screws A and B so there is 1/32-in (.8-mm) more than the width of the metal coil stock width between these entry guides. The flat metal must pass freely between these bars before engaging in the first pair of rollers. For example, to narrow the distance between the guides, move left entry guide to the right by loosening A and sliding the guide toward the middle, leaving the proper clearance for the metal to slide freely when flat. Reverse the adjustment for wider metal.

Figure 8.5: Adjusting for different widths of coil stock using entry guide adjustment screws.

ALWAYS CHECK SIZE OF HEM AFTER CHANGEOVER. The proper dimension for the

hanger-hem is approx. 5/16-in. This dimension may vary slightly after changeover, but should always be checked with a tape measure and a hanger to ensure proper size.

8.8. CHANGING GAUGES OF MATERIAL

Entry Guide Screws B A Left Entry Guide Right Entry Guide

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When changing from one gauge of stock to another, no adjustment is necessary in most cases. Should the product formed be unsatisfactory, the following adjustments may be attempted.

8.8.1. Curvature

Check the bottom corners for curvature and adjust according to regular curvature adjustment procedures in sections 1-6 of this manual.

8.8.2. Rippling of Lighter Gauges

Occasionally, ripples in the gutter bottom will form. This is usually the case when lighter gauges are run (.022 to .025 aluminum and 28 or 29 gauge galvanized steel). Adding pressure (about 1/4 to ½ turn) at stations 3, 4, 5, 6, 7 and 8 will usually alleviate all the ripples. Some upward curvature may result and should be compensated for by repositioning the box unit as in (3A) of the curvature adjustments and (5A) of the crimp adjustment.

8.9. RIPPLING: GENERAL CAUSES

8.9.1. Excessive Pressure of Skate Rollers on Bottom Rollers

Relieve this pressure first at stations 7 and 8 on the right side. Loosen station 7 B and station 8 B 1/4 turn and check results. Lock A and C of both stations when satisfied. Release additional pressure at station 6 if necessary.

8.9.2. Skate Rollers Misaligned with Bends Established at Stations #1, #2, and #3

Lateral Misalignment: Center skate rollers side-to-side using hold down bolts on center of T bar at stations #4 - #8. Feed metal through machine and watch for double tracking of roller skates on bottom corner bends already established.

Figure 8.6: Close up of T bar hold down bolts used to adjust lateral alignment with stations 1-3. T bar hold down bolts

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8.10. ELECTRICAL

• If a particular electrical component does not function properly, begin by inspecting the wiring and connections. Look for any unusual conditions, to include broken or burnt wires, smoke, or unusual noise.

• If needed, wiring diagrams can be obtained from the factory. The diagrams will aid in electrical maintenance.

• Do not attempt to troubleshoot electrical problems if you are neither familiar nor comfortable with basic wiring practices and procedures. Consult your distributor or a qualified electrician if necessary.

8.11. CRASH PROCEDURES

A crash in a roll-forming machine may include any of several conditions: • metal will not move through the machine

• metal is bent or crumpled against a fixed component in the machine • metal is bunching up between forming stations

• the drive train is seized

In any case, a crash presents a potentially hazardous situation for any machine operator. Crashes often produce sharp, jagged metal edges, which ultimately require handling. Suitable hand and eye protection, to include leather gloves and safety glasses, should always be worn when clearing a crash.

8.11.1. Initial Actions

PUSH THE E-STOP IMMEDIATELY!

PLACE THE MOTOR CONTROL SWITCH IN THE OFF/STOP POSITION IMMEDIATELY! UNPLUG THE MACHINE!

Inspect the machine for the cause of the crash. Examine the entire machine, because some obstructions and the crash source may not be either obvious or visible. The safety covers must be removed to conduct an adequate inspection.

8.11.2. Clearing the Crash

Do not attempt to back an entire machine’s length of material out of the entry end of the machine. Also, do not attempt to reverse deformed material backward through a forming station in an effort to flatten it. The machine is not a flattening device, and the bent material will eventually jam in a forming station or the entry guides.

Use snips (this may require both right hand and left hand snips) to cut any folded, bent, or crumpled material out of the machine. Removal of the cut out material may require raising take-up blocks and raising the skate to create enough clearance between forming rolls to slip the pieces of disrupted material out of the machine. In extreme cases, cut the material between every forming station in the machine and slip the pieces out from between the forming rollers and out of the machine.

A severe crash may require partial disassembly to clear, although disassembly is rarely required.

If the crash occurs at the shear, remove the shear from the machine. Clear the machine in accordance with the following steps, then re-mount the shear and proceed with crash recovery procedures.

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Remove material back to a point where the partially formed profile has not been disrupted. At this point, cut a tapered leading edge on material. A rough estimation may be required since cutting a taper onto partially formed material can be difficult.

Cut the coil stock at the entry guides so no additional material feeds into the machine. Clear the machine, taking care to thread the new leading edge.

8.11.3. Crash Recovery

A crash indicates a serious problem with existing adjustments or some kind of mechanical difficulty. Once the machine is clear of material, refer to the machine manual’s “Setup and Operation” Section. Re-read this Section completely. CONDUCT A THOROUGH INSPECTION OF THE MACHINE, and THEN

PERFORM ALL THE PROCEDURES NOTED. Start from the beginning, as if the machine had not

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9. CHANGEOVER PROCEDURES

9.1. GENERAL

Changeover parts for 5-in gutter are colored BLUE and/or stamped 5". Changeover parts for 6-in gutter are colored YELLOW and/or stamped 6". All bolts and set-screws to be moved during changeover are colored RED.

UNPLUG THE MACHINE PRIOR TO PERFORMING ANY CHANGEOVER PROCEDURE

9.2. CHANGEOVER PROCEDURE – 5-in GUTTER TO 6-in GUTTER STARTING AT THE ENTRY END

ENTRY GUIDES: Loosen the four (4) 5/16-in bolts on the topside of the entry guides and slide the

vertical guides toward the outside of the machine until they stop at the end of the slot. Re-tighten the bolts while holding the guide in place.

ROLLER STATION #1: Loosen the three (3) roller locating screws (two outside rollers on top and right

side of bottom roller) until rollers will slide towards outside of machine. Once the roller stops sliding tighten locating screw (locating screws will self align into additional holes).

HEMBENDER ASSEMBLY: (located between stations 1 and 2) Remove the two (2) 3/8-in bolts on the

right side of machine and remove the complete hembender assembly (block and hembender). Replace with the 6-in hembender assembly and tighten into place with the same bolts (6-in assembly is colored yellow).

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ROLLER STATION #2: Loosen the three (3) roller locating screws (two outside rollers on top and right

side of bottom bell roller) just until rollers will slide towards the outside of machine. Once the roller stops sliding tighten the locating screw (locating screws will self align into additional holes).

ROLLER STATION #3: Repeat the procedure used on station #2.

GUIDE BAR: Loosen the guide bar locating knobs and slide the bar all the way to the left side of machine

(guide bar will be repositioned once skate rollers and station #7 are in place).

BOTTOM ROLLER STATION #7: Loosen the locating screw and slide the roller to far left side of

machine (roller will be repositioned once skate rollers are in place).

SIDE ROLLER STATION #8: Remove the 3/8-in bolt on the top side of the roller and remove the roller

(roller will be repositioned once skate rollers are in place).

SKATE ROLLERS STATIONS #4, #5, #6, #7 AND #8: Remove the five (5) 3/8-in bolts that hold the

left side skate rollers in place and remove the rollers from shafts. Replace with 6-in skate rollers (colored yellow) and secure in place with the same 3/8-in bolts.

BOTTOM ROLLER #7 CONTINUED: Slide the roller to the right until there is approximately one metal

thickness between the bottom roller and the skate roller. Align the locating screw into the additional hole and tighten it into place.

Figure 9.2: Station 7 bottom roller changeover. 6-in locating hole 5-in locating hole Roller not shown in this view

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SIDE ROLLER #8 CONTINUED: Replace the side roller and bolt, and tighten the bolt into the additional

hole.

Figure 9.3: Close up of station 8 bottom rollers. The left side roller moves from the 5-in hole to the 6-in hole when changing profiles.

GUIDE BAR CONTINUED: Slide the guide bar to the right until the groove in the support rod is flush

with the end of the support sleeve.

BOX ASSEMBLY: Remove the center bolt on each end of the box assembly and remove the complete

assembly. Replace with the 6-in box assembly (colored yellow) and tighten into place with the same 2 bolts.

5-in hole 6-in hole

Roller not shown in this view.

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CRIMPER ASSEMBLY: Remove the two (2) crimper hold down bolts and move the crimper to the upper

holes in the face plate and secure into place.

Figure 9.4: Close up showing crimper mounting locations for both 5 and 6-in profiles.

SHEAR ASSEMBLY: Rotate the shear so that the blade is in the down position, then remove the four (4)

shear locating bolts and remove shear. Replace with the 6-in shear (colored yellow) using the same bolts.

9.3. MISCELLANEOUS

LEFT SIDE ROLLER BOLTS: Bottom rollers at stations #1, #2, l#3, #4, and #7 are preset and roll

pinned at the factory and should not be moved laterally. To align top rollers #1, #2, and #3, loosen the jam nut on the left side roller bolt, and then thread the bolt in or out to move the shaft/roller laterally. (Right side roller bolts do not need to be moved for lateral adjustment!)

REMOVING MAIN ROLLERS: To remove the main forming rollers, the shafts must be removed from

the machine. To remove a shaft, loosen the jam nut on the left side roller bolt. Turn the shaft until the holes near the left end of the shaft are aligned vertically. Looking into the top hole, locate the roll pin that secures the left side roller bolt to the main shaft bearing. Turn the left side roller bolt until the roll pin is also aligned vertically. Use a punch to knock the roll pin through the roller bolt and out the bottom shaft hole. Take care to support the shaft. Turn the left side roller bolt counter-clockwise until the left end of the shaft hangs free. The right side roller bolt may need to be loosened to create enough clearance to remove the shaft.

THE INITIAL INSPECTION OUTLINED IN SECTION 7 SHOULD BE PERFORMED AFTER EVERY CHANGEOVER

REPLACE THE SAFETY COVERS PRIOR TO OPERATION

6-in crimper holes

5-in crimper holes

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10. MACHINE MAINTENANCE

10.1. CLEANLINESS

Keep both the machine and the surrounding work area clean and free of dust, dirt and debris. Routine cleaning of the entire machine will help extend the life of all mechanical and electrical components. In particular, a clean machine and work area will help prevent the introduction of foreign objects into the machine, which can significantly damage mechanical components.

10.2. LUBRICATION

Every month, oil the following parts with #30 weight motor oil or equivalent: • All sprockets and roller-chain

• All set-screw pressure adjustments • Left guide-cranks and right hem-adjusters

• Blade, guides and other moving parts of the cut-off assembly Every month, grease all gears with axle grease or equivalent. Bearings are self-lubricating, requiring no maintenance

10.3. FORMING-ROLL CARE

10.3.1. Damaged or Marred Roller Surface

Checks and cracks on the roller surface will generally scratch or mark painted coil stock. Eliminated this problem by rubbing out any marks on the roller surface with fine-grade emery cloth.

10.3.2. Dirty Rollers

Solvents, such as mineral spirits, may be used to remove paint, grease, and dirt from the rollers. Galvanized materials will leave a residue on the rollers that will mark painted stock. If changing from galvanized to painted material, clean the rollers with a galvanization remover, such as Galv-Off.

10.3.3. Factory Assistance

In the event of any difficulties you cannot solve with the aid of the manual, call the factory for assistance. We are interested in your satisfaction as a customer.

10.4. ELECTRICAL SYSTEM

10.4.1. Electrical System Components

Each month inspect all the electrical components; look for loose, exposed or frayed wires, loose connections, burned insulation, or any other irregularities. Repair any problems immediately. Do not operate the machine if electrical problems exist. Any problem presents a shock hazard that could cause serious personal injury.

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10.5.1. KR-56A, KR-50A, KR-60A Changeover Lubrication Areas

• Monthly, grease the top and bottom roller shafts at stations #1, #2, #3, and #7. • Monthly, grease the left side skate rollers and shafts where the two slide together. • Twice a year, lubricate all changeover bolts with a spray lubricant or grease.

10.6. STORAGE

If the machine will sit idle for more than one month, the forming rollers should be coated with wax to prevent accumulation of dirt and any corrosion of the forming surfaces.

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11. TRANSPORT AND MOVING

11.1. GENERAL PROVISIONS

During transport/moving, the machine will experience vibration/shock normally associated with vehicular or trailer transport. Without correct preparation, this vibration and shock can severely damage the

machine’s forming rolls. When forming rolls touch or vibrate against one another, the hard chrome plating wears off and the surfaces may fracture. Damaged roller surfaces will scratch/mark painted coil stock, and may cause some rippling in the gutter profile.

In addition, vibration and shock may loosen fasteners. If allowed to vibrate, the forming rolls will not maintain their profile controlling adjustments, which are critical to forming quality gutter profiles.

11.2. PRECAUTIONS

Knudson Mfg., Inc recommends keeping coil stock threaded through the machine during transport.

Material between the forming rolls prevents the rollers from touching one another, reduces possible vibration, and helps maintain critical adjustments. Machines are always shipped from the factory with material threaded through the machine. DAMAGE TO ROLLERS CAUSED BY A FAILURE TO

THREAD THE MACHINE PRIOR TO TRANSPORT/MOVING IS NOT COVERED UNDER ANY WARRANTY. Also, a machine transported without material threaded through it will probably not

maintain its critical adjustments. Expect a substandard gutter profile if this is the case.

11.3. TRANSPORTATION PROCEDURES

Thread the entire machine with metal, taking care not to leave excess material protruding from either end of the machine.

Ensure that all equipment is secure. Do not leave any loose tools in or around the machine. Inspect the mounts identified in Section 6. Verify the machine is securely fastened to the vehicle or trailer bed prior to any traveling.

Disconnect the machine’s power source prior to transport.

If spools or coiled spools will be transported/moved in the uprights on top of the machine or in a cradle, the coil should be secured prior to transport. The spool stops in the spool mounts or the center bars on the cradles should be used to lock the spool/coil during transportation. This will prevent unwinding during transport.

11.4. WHAT TO EXPECT/INSPECT

After transporting/moving the machine, review the procedures listed in Section 6 and carry out any applicable instructions. THE INITIAL INSPECTION OUTLINED IN SECTION 6. SHOULD BE

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