(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.
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
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.
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
Crimper assembly
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 A B
Left Entry Guide
Right Entry Guide
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
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