SAHINLER 4R HMS 30-275 User Manual

4 rolls plate bending machine

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USER'S MANUAL

MODEL 4R HMS 30 - 275

HYDRAULIC 4 ROLLS PLATE BENDING

MACHINE

İzmir Yolu 22.km Mümin Gencoğlu Cad. 16285 BURSA / TURKEY

Tel: +90-224-4700158 (6 lines pbx)

Fax: +90-224-4700770

Web:

www.sahinlermetal.com

Email:

info@sahinlermetal.com

Spare parts & service:

service@sahinlermetal.com

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Summary of Contents for SAHINLER 4R HMS 30-275

Page 1 USER’S MANUAL MODEL 4R HMS 30 - 275 HYDRAULIC 4 ROLLS PLATE BENDING MACHINE İzmir Yolu 22.km Mümin Gencoğlu Cad. 16285 BURSA / TURKEY Tel: +90-224-4700158 (6 lines pbx) Fax: +90-224-4700770 Web: www.sahinlermetal.com Email: info@sahinlermetal.com Spare parts & service: service@sahinlermetal.com...
Page 2 Main Technical Features  Rolls Table Length: 3100 mm  Central Rolls Diameter:  Lateral Rolls Diameter:  Max useful opening between the central rolls:  Rotation Speed: 1.5-5 m/1’  Number of motorized rolls:  Installed power: 11+5,5 Kw ...
Page 3: General Information
GENERAL INFORMATION 1.1 INTRODUCTION The information contained in this document are property of ŞAHİNLER which reserves the right to change, without notice, the characteristics of the product described in this manual and the manual itself.. The ŞAHİNLER is not responsible for inaccuracies due to printing errors or inadvertent errors. And ‘prohibited the dissemination and reproduction, even partial, of this manual without prior written permission of ŞAHİNLER MACHINE.
Page 4 GENERAL INFORMATION 1.2 MANUFACTURER NEWS Sahinler, established in 1953 by Mr. Ismail SAHIN and Mr. Ibrahim SAHIN brothers as a family company, at the beginning produced textile machines, sewing machines later started to produced drilling machines, bandsaws and powerhammers. At 1979 made its first export to Germany. After 1980 with the new structure as joint-stock...
Page 5 We as ŞAHİNLER METAL MAKİNA ENDÜSTRİ A.Ş İzmir Yolu 22. Km Mümin Gençoğlu Caddesi 16285 Bursa – TÜRKİYE confirm that the machine: 4R HMS 30-275 Serial Number: Production Year: 201 ... complies with: MACHINERY DIRECTIVE 2006/42/EC LOW VOLTAGE DIRECTIVE 2006/95/EC ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC and Regulations Applied acc.
Page 6: General Warranty Terms
 Warranty covers only manufacture defective parts and / or components that are reported as “defective” by a Sahinler Technician or the Agent Technician and must be reported to Sahinler in writing by fax or email.  The manufacturer is responsible for the supply of free of charge spares only and cannot be held responsible for loss of work.
Page 7 GENERAL INFORMATION 1.5 PURPOSE – CONTENT – RECIPIENTS - HANDBOOK CONSERVATION ATTENTION PURPUSE: Before starting any operation,installation, testing,commissioning,use or maintenance of the machine is absolutely necessary to consult the manual, which should be read carefully before transporting, installing, using or perform any maintenance on the machine. The operations on the machine should only be done by qualified personnel, who must advance and carefully read the instructions in this manual.
Page 8 GENERAL INFORMATION 1.6 USED SYMBOLS AND CLASSIFICATION OF HAZARD’ In order to increasethe security status, were used in the manual the following symbols(pictograms) to draw thereader's attention and highlight aspects that are particularly important: The term DANGER is used when failure to comply with the regulations or the manipulation of organ scan be a source of injury or serious harm to human health.
Page 9 GENERAL INFORMATION DANGER: FALL DANGER: FIRE DANGER: SUSPENDED LOADS DANGER: TOXIC MATERIALS WARNING: WORKPIECES HIGH TEMPERATURE CAUTION: MOVING PARTS OF THE MACHINE...
Page 10: Other Symbols
GENERAL INFORMATION 1.6.1 OTHER SYMBOLS PROHIBITIONS DUTIES AND REQUIREMENTS NOTE: Notes for the user and other useful information for use.
Page 11 GENERAL INFORMATION 1.7 ADDITIONAL IMPORTANT INFORMATION MAKE SURE that all users have understood the rules of use and meaning of symbols on the machine. Possible accidents can be avoided by following these technical instructions compiled with reference to the relevant EU directives. In anycase always meet national safety standards.
Page 12 SAFETY E RISCHI RESIDUI 2.1 INTRODUCTION The Safety Rules summarize the basic safety guidelines to observe when using the machine. They provide also information about:  Use in accordance with the provisions;  The selection and training of staff;  The scope of work and the work area;...
Page 13 SAFETY E RISCHI RESIDUI ATTENTION The 'Manufacturer Company disclaims any liability for failure to follow Safety Rules and Prevention under the law beyond what is indicated in this manual. ATTENTION It is strictly forbidden to use the machine to operators under the age of 16 years ATTENTION Failure to comply with the requirements in the manual or the possible tampering with...
Page 14 SAFETY E RISCHI RESIDUI 2.2 IDENTIFICATION OF THE MACHINES - PLATES Each ŞAHİNLER machine is equipped with a non-removable nameplate, shown in Figure 1.1, showing the following data: Figure 1.1 – Identification Plate Machine Model Production Serial Number ATTENTION Removing or tampering of the plaque can lead to serious risks for the user and voids the warranty provided by the manufacturer.
Page 15 SAFETY E RISCHI RESIDUI 2.3 TERMINOLOGY Following are defined some recurrent terms. Is a: USER: The person or entity or company that has purchased or rented the machine and that intents to use it for the uses designed for the purpose. This is the machine responsibility and the responsibility of the training to all those that there must operate.
Page 16: Passive Safety
SAFETY E RISCHI RESIDUI 2.4 GENERAL SAFETY RULES In order to ensure the health and safety of people exposed, the ŞAHİNLER machines are equipped with the following safety: passive and active. PASSIVE SAFETY: * Plates reporting dangerous areas; * Ban and obligation plates; * Warning labels.
Page 17 SAFETY E RISCHI RESIDUI ATTENTION It is forbidden to tamper with or replace parts of the machine if not expressly authorized by the ŞAHİNLER Company. The use of accessories, tools, supplies or parts other than those recommended by the manufacturer and/or referenced herein may constitute a danger for operators and/or damage the machine.
Page 18 SAFETY E RISCHI RESIDUI ATTENTION Any ordinary or extraordinary maintenance must be done with the machine without power supply. Do not put hands or introduce screw drivers, wrenches or other tools on the moving parts. The workplace around the machine must be kept clean, tidy and free from objects that may hinder movement of the operator and therefore a great danger to stumbling or whatever.
Page 19: General Warnings
SAFETY E RISCHI RESIDUI GENERAL WARNINGS This manual should be read carefully before using the machine. The user must leave the machine only to qualified and trained personnel for the purpose. The user must take all appropriate measures to prevent unauthorized person from gaining access to the machine.
Page 20 SAFETY E RISCHI RESIDUI ATTENTION The operator must always use the appropriate PPE (Personal Protective Equipment):  Use specific tools for the manipulation of the pieces;  Wear safety shoes, apron, gloves, face shield, headset. The operator must comply with all the signs of danger and caution marked on the machine.
Page 21 SAFETY E RISCHI RESIDUI PARTICULAR TYPES OF HAZARD 2.6.1 ELECTRICITY An electrical shock can result in serious injury and can lead to death. Work on the electrical of the machine can be made according to the rules of engineering, only by an electrician. Open the doors of the cabinet with only the main switch off.
Page 22 SAFETY E RISCHI RESIDUI ATTENTION SAFE USE  Wear appropriate clothing and avoid wearing loose clothing and loose-fitting that could be caught in moving parts. Long hair should be collected. The operator must not bring sharp scissors or tools in pockets. ...
Page 23 SAFETY RISCHI RESIDUI ATTENTION  Periodically check the integrity of the machine in its entirely and its protective devices.  The operator, during operation of the machine, must be in a position to have full control of the entire machine in order to intervene at any time and for any eventuality.
Page 24 RESIDUI PLATE AND SAFETY SIGNALS LOCATION The SAHINLER machine in figure was made adopting all possible solutions for the protection and safety of those working on it. Nevertheless, the machine may have more residual risks, ie those risks that could not be completely eliminated under certain conditions.
Page 25 Figura 2.2...
Page 26: Residual Risks
SAFETY RISCHI RESIDUI 2.10 RESIDUAL RISKS During the normal cycle of work and during maintenance operations Workers are exposed to some residual risks that, due to the nature of operation, cannot be totally eliminated. RISK of ejection of metal fragments. RISK of being hit during the moving of the piece.
Page 27: Product Description
PRODUCT DESCRIPTION 3.1 MACHINE DESCRIPTION This machine is a 4-rolls plate bending machine, particularly suitable for bending  medium and heavy plates with high daily production and high flexibility. The machine equipped with NC can work in automatic for mass production. Steel welded heavy frame construction, thermally stress relieved and machined.
Page 28 PRODUCT DESCRIPTION 3.2 EQUIPMENT AND ACCESSORIES INCLUDED IN THE MACHINE.  Top and Bottom rolls driven with n°2 independent motor-reducer groups.  Hydraulic protection from overloads.  Hydraulic rolls movement.  Double speed working system  Conical bending device.  Control System of the rolls parallelism and their inclination by Electronic-Hydraulic Balancing System.
Page 29 PRODUCT DESCRIPTION 3.4 MACHINE MOVEMENTS CONTROLS 3.4.1.- Controls on the Electrical Cabinet: MAIN SWITCH WITH DOOR INTERLOCK 3.4.2.- Controls on the Mobile Control Panel: See Chapter 5.1 – Page 55...
Page 30: Handling And Installation
HANDLING AND INSTALLATION 4.1 HANDLING AND TRANSPORTATION OF THE MACHINE ATTENTION The user receiving the machine has to make sure that the same has not been damaged and has not been tampered. Should it be necessary to transport the machine for a long journey, the same can be loaded on trucks, rail cars or other means.
Page 31 HANDLING AND INSTALLATION 4.1.1 SPECIFICTION AND LAY-OUT OF THE MACHINE MAIN DIMENSION OF MACHINE Usefull Model A mm. B mm. C mm. D mm. E mm. Length 4R HMS 30 – 275 3100 5000 1600 1800 Figure 4.1 The layout in Figure 4.1 shows the main dimensions of the machine. Note: For safety issue always leave free space around the machine, that area will also depend on work being done.
Page 32: Unpacking Of The Machine
The packing material is completely safe and do not consist any environmentally dangerous articles. However they must be kept out reach of children as some nylon products in packing may cause suffocation if used as a toy etc. 4.1.3 LIFTING THE MACHINE APPROX MACHINE WEIGHT : 4R HMS 30-275 9.5 TON...
Page 33: Transport And Lifting
HANDLING AND INSTALLATION 4.1.4 TRANSPORT AND LIFTING When transporting, the components of the machine must be well anchored with ropes or chains attached to the transport plan, in order to avoid that, during this phase, may be slipping and tipping over the same resulting projections beyond the means of transport, which could cause damage to persons and/or property, as well as cause damage to the machine.
Page 34 HANDLING AND INSTALLATION DANGER The lifting and transport can be very dangerous if not done carefully: keep away any outsider or unauthorized person, clear and delimit the area of transfer, verify the integrity of the available resources. Before the lifting, make sure that all moving parts of machinery have been blocked. Never manually keep machine parts in case of precarious stability.
Page 35 HANDLING AND INSTALLATION 4.1.5 BARRIERS LIMITING DANGER ZONES During processing is important: Define the work space; Indicate the danger with proper signage; One person should operate the machine. In relation to the technical and operating characteristics of the machine, it is therefore necessary to delimit the work area with appropriate barriers and indicate the danger with proper signs.
Page 36: Dangerous Areas
HANDLING AND INSTALLATION DANGEROUS AREAS Dangerous areas listed below must be kept clear during the bending operation. 4.1.6 TEMPORARY STORAGE In the event that the machine should remain outdoor for a short period, prior to being transported in, the user must provide to cover it with sturdy nylon sheeting. If storage is longer than two-three days, it is necessary for this to happen in a place protected from weathering and by temperatures too high and too low.
Page 37 HANDLING AND INSTALLATION 4.2 INSTALLATION After verifying the integrity, the user can install the machine in mind that has the responsibility to ensure that: ATTENTION  The intended location is sheltered from the elements;  The support area is perfectly flat and with load capacity adequate to the weight of the machine;...
Page 38: Foundation Plan
4.2.1 FOUNDATION PLAN...
Page 39: Electrical Connection
4.2.2 ELECTRICAL CONNECTION Before making the electrical connection, check that the power supply be equipped with an efficient equipotential bonding in accordance with applicable electrical standards. This is a specific responsibility of the User. The electrical equipment of the machine is prepared, unless otherwise specified by the Buyer, to operate at a voltage of 380V and a frequency of 50 Hz.
Page 40 HANDLING AND INSTALLATION DANGER It is essential to correctly perform the electrical connections. It is recommended to carefully follow the instructions below, using the functionals schemas in the Annexes to this manual. ATTENTION In order to ensure proper functionning of the entire electrical equipment, the values of the voltage of the machine may not differ with respect to nominal declared under contract beyond the percentages required by law.
Page 41 HANDLING AND INSTALLATION DANGER It is forbidden to connect the machine directly to the electrical conductors of the distribution plant, a failure on the system of distribution can result in serious injury to the Operator and irreparable damage to the machine electrical equipment. It is mandatory to always turn off the power to intervene whenever the power connections.
Page 42 The electrical cabinet has a locking wrench and a switch “interlock”. This prevents the opening of the cabinet door with the equipment energized. It must be to bring the switch from position 1 to position 0 before opening the door. ATTENTION For safety of personnel, the earthing system of the plant must be efficient.
Page 43: Motor Voltage
4.2.3 MOTOR VOLTAGE...
Page 44: Motor Starting
HANDLING AND INSTALLATION 4.2.4 MOTOR STARTING ATTENTION ELECTRIC VOLTAGE Before using the machine you must perform the following: JUST WRONG Open the protective cover and check the direction of motor rotation. If the direction of rotation is wrong to reverse the wires L1-L2 with each other.
Page 45: Reverse Power Protection
HANDLING AND INSTALLATION 4.2.5 REVERSE POWER PROTECTION Yellow - OK Siemens o similar If the electrical connection of the machine is wrong, the protection device is activated and blocks all phase electrical protection, in order to protect the pump from reverse rotation which could cause burning of the same.
Page 46: General Inspection
HANDLING AND INSTALLATION 4.2.6 PRELIMINARY CLEANING OF THE MACHINE Before and after placement, the machine itself must be thoroughly cleaned. Before proceeding, you must remove the power supply by bringing to “0” the main switch. 4.2.7 GENERAL INSPECTION Check that there is no corrupted items and that all components are installed correctly. Safety devices are unsafe or damaged parts must be repaired or replaced by qualified personnel before the commissioning of the machine.
Page 47: Start-Up And Use
START-UP AND USE 5.1 First Start and Control Console The machine is equipped with a phase controller. If the electrical connection is not  correct the machine will not start. Reverse the position of power cables and try again (see also Chap.
Page 48 START-UP AND USE 5.2 Normal Operation Read the instructions on the control panel before using the machine. The description of the electrical panel is inserted in the last chapter of the manual. The schema of the control panel with a description is given below. Power light on –...
Page 49: Emergency Stop
START-UP AND USE 5.3 EMERGENCY STOP The machine has one Emergency Stop (2) and Emergency Stop wire around the machine. If the machine is stopped by pushing one of these the PLC must be reset before starting. To restart after an emergency stop: Release the Emergency Stop Button (2) or ...
Page 50 START-UP AND USE 5.6 CYLINDRICAL BENDING OPERATIONS Pre – bending is the operation where the edges of the material is bent to the same radius of the end radius. This is used to get best results in full circle bending Before Operation ;...
Page 51 START-UP AND USE FIRST OF ALL , AS SHOWN IN FIGURE, PLACE THE ROLL B AND INTRODUCE THE PLATE AMOUNG THE ROLLS. fıgure 1 LIFT THE ROLL D AND PINCH THE MATERIAL fıgure 2 USING THE ROLLS ROTATION BRING THE END OF THE PLATE TO THE CENTRE OF THE CENTRAL ROLLS.
Page 52 START-UP AND USE CARRY OUT THE PRE-BENDING LIFTING THE SIDE ROLL C , AFTER CHECKED WITH THE TEMPLATE IF THE RADIUS OF THE OBTAINED CURVATURE IS EQUAL TO THAT YOU WANT, MAKE A SMALL ROTATION. WISHING, TRANSLATING THE PLATE SO THAT THE SECOND END IS AMOUNG THE ROLLS, THE PRE-BENDING OF THIS END MAY BE OBTAINED.
Page 53 START-UP AND USE fıgure 7 fıgure 6 NOTES Start rolling the material until you get the required radius. It is normal to make several passes before getting the job done but remember that with less passes you get better finished material. If you are working with stainless steel it is important to finish the job in a few passes.
Page 54 START-UP AND USE 5.7 CONICAL BENDING ALTHOUGH THE BENDING PROCEDURE IS THE SAME AS PER THE CYLINDRICAL BENDING, WHILE MAKING THE CONICAL BENDING YOU FIRST NEED TO TILT THE ROLLS AS SHOWN IN FIGURE AND THEN PUT THE SIDE OF THE SHEET CORRESPONDENTING TO THE SMALL DIAMETER OF THE CONE AGAINST THE CONICAL BENDING DEVICE.
Page 55: Welding Operation
START-UP AND USE 5.8 WELDING OPERATION ATTENTION: Before welding operation switch off the electricity from the general switch WRONG TRUE...
Page 56: Inspection And Maintenance
INSPECTION AND MAINTENANCE PRE LIMINARY REMARKS The robustness of the machine and the precautions taken at the design stage, means that the machine requires very little maintenance that in any case must be performed regularly. GENERAL RECOMMENDATIONS (SEE ELECTRICAL AND HYDRAULIC DIAGRAMS IN CHAPTER 8) Before carrying out any work to read the instruction in this manual.
Page 57 INSPECTION AND MAINTENANCE ATTENTION The regularly scheduled maintenance cannot be done when the machine is running. Then unplug the power supply through the main switch and the socket. A warning signal that says “DO NOT START – MACHINE MAINTENANCE” must be clearly visible on the machine.
Page 58 INSPECTION AND MAINTENANCE LUBRICATION The machine needs to be lubricated regularly for it to work efficiently and for a long time. In Figure 6.3 highlights the points where to manual lubricate according to the attached sheet: FIGURE 6.3...
Page 59: Machine Cleaning
INSPECTION AND MAINTENANCE MACHINE CLEANING During processing the machine (in particular the area of the rolls and the guides) is covered with slags and residues of bending operations, it is therefore advisable to clean the machine regularly. To make this clean absolutely to avoid blowing with compressed air, since slags tend to get inside the machine.
Page 60: Working Hours
INSPECTION AND MAINTENANCE MAINTENANCE Control all the bolts of the machine and the reducers periodically once a month, in particular: * After the first 2 weeks of work or 100 hours after start-up: - Filters of the hydraulic system, - Oil leaks, - Gearbox bolts.
Page 61: Recommended Grease
INSPECTION AND MAINTENANCE Comparative Table of hydraulic oils: Working Temperature Brand Working Temperature > 20 °C < 20 °C Agip OSO 46 OSO 32 Energol HLP 46 Energol HLP 32 Castrol Hyspin AWS 46 Hyspin AWS 32 Elfona 46 Olna 32 Esso Nuto H 46 Nuto H 32...
Page 62 INSPECTION AND MAINTENANCE PERIODIC CHECKS OF THE RETURN FILTER Check to return Filter Clean or change the filter as follows: Open the cover ( Nr.1) by turning it to counter- clockwise Clean or change the filter element Close the cover by turning it to clockwise Check to Suction Filter (Inside) Below we explain step by step to change the suction filter...
Page 63: Extraordinary Maintenance
INSPECTION AND MAINTENANCE EXTRAORDINARY MAINTENANCE The extraordinary maintenance operations are not covered in this manual, as they must have been made by manufacturer or by authorized personnel from the same. AFTER SALES SERVICE ATTENTION IT IS ABSOLUTELY NOT RECOMMENDED THE USE OF NOT ORIGINAL SPARE PARTS.
Page 64: Machine Demolition
MACHINE DEMOLITION WASTE DISPOSAL MACHINE DEMOLITION ATTENTION THE DISASSEMBLY AND DEMOLITION AND/OR SCRAPPING OF THE MACHINE MUST BE PERFORMED BY QUALIFIED PERSONNEL The machine is an asset for it is demolition follow the regulations imposed by the country’s laws regarding the alienation of goods. Prior to demolition (if necessary) request an inspection by relevant authorities and verbalization..
Page 65 MACHINE DEMOLITION WASTE DISPOSAL WASTE DISPOSAL ATTENTION For disposal of various components, contact only facilities legally authorized and able to issue a receipt to disposal. The disposal of materials constituting the packaging, replaced parts of components or machine must be done in an environmentally, avoiding pollution of soil, water, air. Will be the responsibility of the recipient to do this in accordance with current standards in the country in which the machine is used.
Page 66 HYDRAULIC DIAGRAMS AND PART LIST...