INSTRUCTIONS FOR USE

Via dell’Industria, 19
25010 - VISANO (Brescia) Italia

4 rolls bending machine

mod. 4HEL

MxU4R Rev. 01/2011

Original
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 2 / 58

CONTENT OF THE MANUAL

1 INTRODUCTION ..........................................................................................................................4
1.1 FONTS AND DEFINITIONS ....................................................................................................................5
2 LIFTING AND TRANSPORT ........................................................................................................6
2.1 METHODS OF TRANSPORT..................................................................................................................6
2.2 STORAGE ...............................................................................................................................................6
2.3 LIFTING-TRANSPORT............................................................................................................................7
3 PROCEDURE FOR INSTALLATION............................................................................................9
3.1 PLACEMENT OF THE MACHINE ...........................................................................................................9
3.2 FOUNDATIONS.......................................................................................................................................9
3.3 LEVELLING ...........................................................................................................................................10
3.4 ELECTRICAL CONNECTION ...............................................................................................................14
3.5 INSTALLATION OF THE EMERGENCY ROPE ...................................................................................15
4 PRELIMINARY OPERATION .....................................................................................................16
4.1 TESTS ON THE MACHINE ...................................................................................................................16
4.2 TEST OF THE ELECTRICAL CONNECTIONS ....................................................................................18
5 DESCRIPTION OF THE MACHINE ............................................................................................19
5.1 WORKING SYSTEM .............................................................................................................................20
5.2 CONTROLS DESCRIPTION .................................................................................................................20
6 DIRECTIONS FOR USE .............................................................................................................21
6.1 AUTOMATIC START IN NORMAL CONDITIONS ................................................................................21
6.2 START THE MACHINE AFTER A BLACK OUT ...................................................................................21
6.3 STOP THE MACHINE IN NORMAL CONDITIONS ..............................................................................21
6.4 STOP IN CASE OF EMERGENCY .......................................................................................................21
6.5 RESTART AFTER ANOMALY...............................................................................................................22
6.6 RESTART AFTER EMERGENCY .........................................................................................................22
6.7 MANUAL START IN NORMAL CONDITIONS ......................................................................................22
6.8 START THE MACHINE AFTER A BLACK OUT ...................................................................................22
6.9 STOP THE MACHINE IN NORMAL CONDITIONS ..............................................................................22
6.10 STOP IN CASE OF EMERGENCY .......................................................................................................22
6.11 RESTART AFTER ANOMALY...............................................................................................................22
6.12 RESTART AFTER EMERGENCY .........................................................................................................22
6.13 POSITION OF THE OPERATORS DURING THE ACTIVITY OF THE MACHINE...............................23
6.14 PERSONAL PROTECTIVE EQUIPMENT.............................................................................................24
6.15 MOVEMENT OF THE PLATES .............................................................................................................25
6.16 WORK PIECE PRODUCTION...............................................................................................................26
6.17 ROLLS PARALLELISM .........................................................................................................................30
6.18 PINCHING ROLL PARALLELISM .........................................................................................................30
6.19 EXECUTION OF A CONE .....................................................................................................................31
6.20 WORK PIECE EXTRACTION................................................................................................................37
7 OPERATING ANOMALIES ........................................................................................................39
7.1 CONICAL DEFECT ...............................................................................................................................39
7.2 ALIGNMENT DEFECT ..........................................................................................................................39
7.3 BARREL DEFECT .................................................................................................................................40
7.4 PINION DEFECT ...................................................................................................................................40
7.5 IRREGULAR EDGE...............................................................................................................................41
7.6 STRAIGHT EDGE TOO LONG .............................................................................................................41
7.7 EDGE TOO CLOSED ............................................................................................................................42
8 INCORRECT USE OF THE BENDING MACHINE......................................................................43
8.1 MACHINE TURNED OFF WITH THE TOP ROLL TILTED ...................................................................43
8.2 OPENING OF THE PINCHING ROLL...................................................................................................43
8.3 ROLLING OF PROFILES BETWEEN THE ROLLS ..............................................................................44
8.4 GRINDING OF THE PLATE ..................................................................................................................44
8.5 WELDING OF THE FERRULE ON THE MACHINE .............................................................................44
8.6 ALTERATION OF THE PERFORMANCE LIMITS ................................................................................44
8.7 REMOVAL OF THE MEMORY CARD ..................................................................................................44
9 MAINTENANCE .........................................................................................................................45
9.1 ORDINARY MAINTENANCE.................................................................................................................46
9.2 OIL TANK AND HYDRAULIC UNIT ......................................................................................................49
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 3 / 58

9.3 MAINTENANCE OF THE ELECTRICAL INSTALLATION ....................................................................52

10 PROTECTION AND EMERGENCY DEVICES ........................................................................53
10.1 PROHIBITIONS AND OBLIGATIONS FOR THE OPERATOR’S SAFETY ..........................................54
11 DECOMMISSIONING OF THE MACHINE ..............................................................................57
11.1 INSTRUCTIONS FOR DECOMMISSIONING .......................................................................................57
11.2 DISASSEMBLY OF THE MACHINE FOR ABANDONING ...................................................................57
12 ANNEXES...............................................................................................................................58
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 4 / 58

BEFORE STARTING ANY ACTIVITY WITH THE MACHINE, IT IS OBLIGATORY TO READ

THIS MANUAL.

There might be a difference between the images in the manual and the exterior features of the machine
delivered: such differences are just aesthetical and do not affect the functionality of the machine.

1 INTRODUCTION

This manual refers to the 4 rolls bending machine model 4HEL and was written for the whole series of
4HEL machines, that can have rolls of different length and diameter. It contains the necessary
information for the identification of the machine, instructions on transport and movement, adjusting,
use, maintenance and decommissioning.

The 4 Roll bending machine model 4HEL has been projected and manufactured for plate bending.
The machine, provided with a feeder device and control, is delivered to the customer with the CE
mark of conformity in compliance with the model II A included in the Machine Directive.

The information on the CE plate is:

Name and address of the manufacturer

CE mark
Type of machine
Serial number
Year of manufacture

(Example of identity plate)

The machine can be used only by one operator

The machine is produced with the safety devices necessary to grant the safety and the health of the
operators, as required by these laws and the technical normative in force. Every machine is delivered
in perfect working order, after being rigorously tested in our works at its maximum performance
capacity.

Any modification to the machine without the authorization of the manufacturer is not allowed. The
manufacturer does not allow any improper use.

If the instructions in this manual are not respected, even partially, the safety of the workers can be put
at risk and/or damage to the machine can be brought about: therefore, in this case FACCIN s.r.l.
denies civil and penal liabilities: the employer must ensure proper training of the personnel, in
compliance with the CE directives relating to the safety and the health of the workers, according to the
qualification of the personnel.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 5 / 58

The machine has always to match the safety requirements, performing ordinary and periodical
maintenance that is later indicated in chapter “MAINTENANCE”; is in order to reduce the risks for the
operators and for those who work near the machine.

The guarantee of smooth functioning and full performance is strictly dependent on the
compliance with the directions for use described in this manual. Condition of application of the
warranty are specified in the contract between supplier/customer.

According to the law in force, this manual is a component of the machine. It has to be retained during
the whole period of the technical life of the machine and has to be readily available. It has to be
updated every time procedures are modified or safety elements are replaced. Any supplement that
the manufacturer might send to the customer in later period has to be retained with the manual.
In case the machine is sold, as used machine, the manual has to be delivered with the machine.
FACCIN Srl is not responsible for damages caused by the wrong interpretation of the content of the
manual, due to the fact that it is difficult to read because of deterioration or it is incomplete for any
reason. In case the manual is damaged, lost or anyway not available, a copy must be requested to
the manufacturer.

The manufacturer reserves the rights to the material and intellectual property of this publication, and
forbids any duplication of any form, even partial, without his previous written assent.
Any reproduction, copy or diffusion of this manual is a violation of the law and will be prosecuted by
the manufacturer.
For any further information contact:
FACCIN S.r.l. Via dell’industria, 19 - 25010 VISAN0 (BS) ITALIA
Telephone: 030 9958735 – fax: 030 9958771 - e mail: info@faccin.com

1.1 FONTS AND DEFINITIONS

«ATTENTION!» in «bold» underlined characters with its relating text in «bold» not underlined
characters: it highlights a potentially dangerous situation for the safety of the operator and
others;

«WARNING» in «bold» characters with its relating text in «normal»: it highlights the potential
for the misuse of the machine;

SYMBOLS with a relating text: they highlight visually and unequivocally the topic, which is
particularly important for both the safety of the operator and others, and for the correct use of
the machine;

FERRULE: plate sheet curved as a cylinder or a cone

PREBENDING: initial phase of the bending process consisting of the bending of the plate
edges, before proceeding with the ferrule bending.

RELEASE: mobile arm – when open, it allows the ferrule extraction

EJECTOR: system for the clearance of the finished ferrule
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 6 / 58

2 LIFTING AND TRANSPORT

2.1 METHODS OF TRANSPORT
The machines are sent to the destination or to the port, packed as follows, according to the means of
transport. Different conditions must be agreed in the contract.

- SHIPMENT BY LAND: The machine is wrapped in a dust repelling film and fixed to the box of the
truck. The equipment is sent disassembled on pallets and is wrapped in a dust repelling film. The
fastening of the machine to the means of transport is responsibility of the forwarding agent who
carries out the operation, instructed by Faccin Srl personnel.
- SHIPMENT BY SEA: Usually the machine sent in a container is fastened to the container. Upon
request of the customer it can be sent in a wooden crate (and protected by a protection sheet
fastened at the base) containing bags of hygroscopic salts for the protection from corrosion of the
manufactured parts. The dimensions of the complete crate or container depend on the type of
machine

NOTE: In relation with the length of the trip and the atmospheric conditions (high moisture), it is
possible that, at destination, the rolls show a coat of rust: this does not mean any working problem.

2.2 STORAGE
The machine must be stored following these instructions:

- it is essential not leave the container or the wooden case containing the machine and other
equipment outside before the machine is installed;
- be sure that the machine is stored in a dry place sheltered from the rain and in environmental
conditions suitable for work;
- do not stack two packages one upon the other;
- the packing has always to be handled with care in order to avoid damage to the machine inside;
- in case the packing is stored for a long time before the machine is installed, it is necessary to
check periodically that the packaging is not damaged.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 7 / 58

2.3 LIFTING-TRANSPORT

Lifting/transport must be carried out exclusively with crane or gantry-crane.

In the following pictures/diagrams you can see how the load can be moved when the machine is
contained in one or more load-bearing crates or container. The barycentre of the packing is in a
position that prevents it from reversal during the operations of movement and storage. In any case the
base of the crate is provided with housings that allow safe slinging of the lifting apparatus. Weight
and size of the machine are specified in Section 10, Annexes.
For the handling of normal crates (not load-bearing), please refer to the following paragraph (2.3.2).
Whatever lifting procedure you choose, you have to use adequate bands and ropes according to
normative EN 1492-2.

Lifting a load is always a dangerous operation: therefore, it has to be performed

by qualified personnel in compliance with the law as it stands.

2.3.1 HANDLING OF LOAD-BEARING CRATES OR CONTAINER

Lifting in narrow room

Lifting in large room

Lifting with telescopic

spacers
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 8 / 58

2.3.2 HANDLING OF NON LOAD-BEARING CRATES

The handling of the machine contained in non-load-bearing crates must be made by slinging the top
roll, as detailed in the following paragraph (2.3.3).
It will be necessary to remove the crate cover. The crate is fixed to the machine and moves with it.

Do not lift the crate! It is not load-bearing! The crate might break up and let the
machine fall.

2.3.3 MACHINE LOADING / UNLOADING

For correct loading/unloading of the machine (not packed in wooden crate) and for an adequate
transport of the machine when it is possible to move it without disassembling it, operate as instructed

• Remove the dust repelling film.

• Make sure that the release (1) is
completely closed and the screw that
locks the release arm (3) is
tightened).
• Pass the slinging bands (2) big
enough round the top roll as showed
in the picture.
• Verify that the load is perfectly
balanced in order to avoid
dangerous band slipping.
ATTENTION: lift the load of a few
centimetres only (4 – 5 cm) from
the floor.
• Start lifting only after you have
verified that the load is balanced.

In case there are no bands available to

lift the machine, it’s possible to use wire
ropes (3) together with a rockerarm (4).
• Check that the release (1) is
completely closed with screw in the
centre.
• Cover the top roll with smooth
material (2) such as fibre or cloth.
• Pass the wire rope (3) big enough
round the top roll as showed in the
picture.
• Verify that the load is perfectly
balanced in order to avoid
dangerous band slipping.
ATTENTION: lift the load of a few
centimetres only (4 – 5 cm) from
the floor.
• Start lifting.

In case of loading/transport make sure that the machine is well fixed in order to avoid accidents.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 9 / 58

3 PROCEDURE FOR INSTALLATION

3.1 PLACEMENT OF THE MACHINE

The machine must be installed according to the instructions in the foundation plan, in a covered place
and possibly indoor, on a flat and levelled surface.

The machine must not be installed outdoors: the electronic, hydraulic and mechanic components
might be damaged if exposed to the weather and cause malfunction and/or alteration of the
parameters (electronic elements such as transducers, potentiometers, are not protected against liquid
penetration). The machine is not arranged to work at very low temperature (closet o 0° C or lower).
Electronic, hydraulic and mechanic components might lose their normal isolation, fluidity and
resistance. Even the plates to be bended, at low temperature, are more fragile and risk to break.
Also high temperature is as dangerous. The enclosed sheets indicate the correct temperature
operation range for electronic components.
High room temperature can lead to overheating of hydraulic oil, it is therefore necessary that
temperature does not exceed 50° C.

Verify that the following conditions are satisfied:

- There must always be enough room for access on any side of the machine, so that i twill be
possible to work on it without difficulty.
- There must always be enough light on the machine, in particular in the areas interested by
maintenance or other interventions.
- The floor must be perfectly flat and levelled to avoid deflections of the frame during the operation.

Big machines, when the working height would be too high for the operator, must be placed in a pit.

ATTENTION: The customer must ensure the pit is made safe using the correct plates around
the machine immediately after the placement of the machine in order to prevent personnel
from falling.

It is absolutely forbidden to use the machine without its proper covering.

3.2 FOUNDATIONS

For correct positioning and consequent smooth functioning, the machine has to be placed upon and
anchored to an adequate concrete foundations.

Foundations have to be suitable for the machine weight and size also considering the machine
functions.

When the machine has been correctly positioned, fix it with suitable chemical fixing bolts (please refer
to the foundation plan in section “Annexes”).

Before carrying out any bending test, respect the application time indicated on the technical data of
the chosen chemical fixing.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 10 / 58

3.3 LEVELLING

In order to achieve correct position and levelling of the machine, check two types of levelling:
TRANSVERSAL and LONGITUDINAL.

TRANSVERSAL LEVELLING

- Remove the screw that blocks the drop end release.

- Open the hydraulic release “B”
- Pull up and push down the top roll “C” (if the machine is provided with inclination)
- Close slowly the hydraulic release “B” paying attention that the "A" top roll block matches exactly
with the "B" release.
- If necessary, introduce some plate pieces until the perfect levelling is reached, as shown by the
diagrams.

If the machine is as per diagram 1, the

“shim” will have to be placed under the
machine frame on the right.

Diagram 1
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 11 / 58

If the machine is in the condition shown in

diagram 2, the “shim” will have to be placed
under the machine frame on the left.

Diagram 2

The condition when the machine is correctly

aligned is when the drop end release
matches exactly the top roll block.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 12 / 58

LONGITUDINAL LEVELLING

After verifying the transversal levelling is correct, carry out the following instructions:

Lay a straight edge on the machined surface of the back housing (STRAIGHT EDGE 1) and a further
straight edge on the machined surface of the front housing (STRAIGHT EDGE 2). Check the
parallelism between the two edges.

In the event that A and B have different measurements, raise the machine using the correct means
(ex. bridge crane) and insert some “shims” as shown in the diagrams.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 13 / 58

NOTE:
Check that under the pistons of the
pinching roll there is always contact
between the frame and the floor. If
necessary, insert some plate crop ends
in order to avoid the frame deflection
during the plate-pinching phase.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 14 / 58

3.4 ELECTRICAL CONNECTION

The electrical connection must be carried out by qualified personnel.

During any operation of installation, unmistakable warning signs must be used, bearing the following
indication:

MACHINE BEING INSTALLED!

Before connection to the electrical net, check that the line voltage corresponds to the one prearranged
on the machine and indicated in the technical data (Section “Annexes”).
Connect the 3 phases on the electrical terminal board (2) with the general switch ( in the drawing
below) open (position 0).

WARNING: The incautious removal of the memory card can cause the loss of all the data of
the machine and the programs saved, therefore the memory card mustn't ABSOLUTELY be
removed without the authorization of the Technical Service FACCIN.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 15 / 58

3.5 INSTALLATION OF THE EMERGENCY ROPE

For the correct functioning of the machine it is necessary to install correctly the perimeter cable.

The installation of the emergency rope must be carried out by qualified personnel.

First of all place the SUPPORT – ANGLE GEARS – CABLE – ELECTRICAL SWITCH as shown in
the drawing below.

Tension the cable until both contacts are closed (the edge of the BLACK small rod must be placed
near the GREEN ring area). Only in this position is it possible to start the machine.

To reset the perimeter cable, lift the BLUE button as indicated in the drawing.

The removal and every change of operation on the emergency rope constitute
alterations of the machine and thus exonerate FACCIN from every and any
responsibilities in case of accident.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 16 / 58

4 PRELIMINARY OPERATION
4.1 TESTS ON THE MACHINE
Before starting the machine carry out the following instruction:
1. Check all of the screws for all gear boxes and flexible hoses to assure there are no loose
connections.
2. Fill the tank (1) of the hydraulic power unit with oil ISO HV/46 (or other as indicated in the table
in chapter MAINTENANCE) by means of the filling plug (2); verify the correct level using a
suitable dip stick or the oil level gauge (3) placed on the tank side. Make sure that the taps
connecting the tank to the hydraulic pump are open.
3. Verify that the planetary gear oil is at the right level by means of the gauge (4) set on the side.
If needed, top up.

4. Ensure lubrication by means of the pump lever (optional) or through the different lubrication
points mounted on the machine. Please refer to the layout of the lubrication points in chapter
“Maintenance”.
5. Check that all hydraulic and other auxiliary connections are correctly arranged.
6. Make sure that all panels are fixed on the frame. The machine must not work without its
casings.
7. When the machine is delivered to the customer, the rolls are coated with a light oil coating for
protection. Before using the machine, the oil must be removed in order to avoid that the plate
slips out of the rolls.
8. Remove the screw that blocks the release.
9. Verify the correct operation of emergency devices (rope and mushroom head button)
10. Verify the correct operation of the limit switches.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 17 / 58

4.1.1 Limit switches function

Before starting to use the plate bending machine, check the good functioning of the limit switches.
NOTE: The number and position of limit switches varies according to the machine type.

SQ1 This limit switch indicates the closing of the release. If SQ1 is not correctly positioned it can
cause a bad closing of the release or (if it is not pushed) it does not allow the rolls rotation.
Verify the integrity of this limit switch trying to open/close the release through the proper
control (see section 5.2 “Machine controls”).

SQ2 This limit switch (which is present only on the machines provided with inclination of the top roll
or machines with numerical control) indicates that the release is completely open and so
allows the inclination of the top roll. The wrong positioning can cause an incomplete opening of
the release or forbid (if not pushed) the inclination of the higher roll. Verify the integrity of this
limit switch trying to open/close the release and tilt the top roll through the proper controls (see
section 5.2 “Machine controls”)

SQ3 (only on machines provided with inclination) This limit switch indicates that the higher roll is in
horizontal position and it is always pushed during the normal bending operations. Only once
the top roll is inclined it is not pushed, and in this condition it forbids any movement of the
machine.

WARNING: If during the normal work of the machine (i.e. with the higher roll not inclined) SQ3 is not
pushed, any movement of the machine will be immediately stopped.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 18 / 58

4.2 TEST OF THE ELECTRICAL CONNECTIONS

This operation must be carried out by qualified personnel.

1. Check that the machine frame is correctly connected to the grounding (earthed) with a metallic
connection
2. Before switching on the machine, check that its ground (earth) cable (in the electric box) is
connected with a ground (earth) cable of the main electrical system of your plant.
3. Check that the pump rotates according to the arrow on the pump body. To do this it is
necessary to start the machine for a few seconds, using the command on the control panel. If
the rotation is not correct, change the connection of 2 of the 3 phases on the terminal board,
so that the rotation of all motors will be reset.
WARNING: Don’t exchange the phases on the electric motor board, but only in the main
electric box board.
IN CASE THIS INSTRUCTION IS NOT RESPECTED, THE PUMPS COULD BE DAMAGED
AND THE MACHINE WILL NOT WORK AT ALL.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 19 / 58

5 DESCRIPTION OF THE MACHINE

The machine model 4HEL is designed for the cold bending of steel, stainless steel and aluminium
plates. It is also possible to bend other materials (alloys and miscellaneous materials), provided that
the procedure is technologically possible.
It is possible to achieve different rolling profiles: circular, oval, polycentric, truncated cone bending.
Other uses are not allowed.

The machine characteristics do not allow reaching a bending radius smaller than the radius of the top
roll.

Figure 1 – Machine parts

NOTE: to make the drawing interpretation easier, the protection systems have been omitted
Legenda:
1) Frame 9) main motor
2) back upright 10)lower gearbox
3) fore upright 11)lower motor
4) top roll support with release 12)lateral cylinder
5) top roll 13)pinching cylinder
6) lower roll 14)conical bending device
7) lateral roll 15)inclination (optional)
8) main gearbox 16)casing

The electric board can be installed on the right or

rear side of the machine. It is equipped with
hinged door with a mechanical lock, and general
switch with door-blocking device.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 20 / 58

This manual is referred to the basic machine, as showed by the above picture. Upon request, the
machine can be provided with the below listed accessories. For further information on the use of
these accessories please contact our Service Dept. at the numbers given in Chapter 1.

• Supplementary motorization of one or both side • Ejector

rills • Simple feeding table
• Side support • Feeding table with plate alignmenet system
• Central ferrule support • Plate loader on the feeding table
• Central support with hydraulic pulling function • Clearance system
• Co-ordinated central support, vertical and
horizontal

5.1 WORKING SYSTEM

The four rolls of the machine all moving by means of hydraulic actuators. The roll movement can be
obtained through the control station during manual working or through PLC during automatic
functioning. The machine described in this manual can perform circular or tapered ferrules (for the
latest, the machine must be equipped with the appropriate accessory).

WARNING: The incautious removal of the memory card can cause the loss of all the data of
the machine and the programs saved, therefore the memory card mustn't ABSOLUTELY be
removed without the authorization of the Technical Service FACCIN.

The machine parameters such as speed, thrust, and torque are determined by modulating pressure
valves and are calibrated during the testing by FACCIN qualified personnel.
WARNING: The modulating valves of thrust or torque mustn’t be tampered to try obtaining
performances different from what specified in section ANNEXES; this might compromise the safety of
the machine and lead to parts or mechanical breakdown.

5.2 CONTROLS DESCRIPTION

Please refer to the hard copy of the manual delivered with the machine.

ALL MACHINE CONTROLS ARE DETENT CONTROLS, SO THEIR ACTION

STOPS WHEN PUSH-BUTTON OR JOY-STICK IS RELEASED.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 21 / 58

6 DIRECTIONS FOR USE

The following sections explain how to:

- Start the machine in normal conditions
- Start the machine after a black-out
- Stop the machine in normal conditions
- Stop the machine in case of emergency
- Restart the machine after anomalies

Before starting the machine 4HEL, it is necessary to check that all switches, selectors
and joy sticks are working correctly.

6.1 Automatic start in normal conditions

1. Turn the general switch on the door of the electrical gear box to pos. 1. The white warning light
on the control station will switch on. After this operation, an electric resistance inside the
hydraulic tank will take the oil temperature to the set value. To this purpose, if the machine is
not to be used for at least two days, the switch must be turned to pos. 0 (zero).
2. Turn the key selector on the control station; after a few seconds the green light beside the key
will switch on.
3. Turn the PC selector to ON and push the button beside. In case the machine is equipped with
Siemens panel, this will automatically switch on when the machine is started.
4. Turn the selector of operation mode to MAN. This function enables the different movements of
the machine while the control is pressed; if the control is released the movement stops.
5. Use the single controls available on the control station, described in section 5.2.

Operation mode AUT concerns a completely automatic process; this means that PLC must be
correctly programmed for the product you wish to obtain. Press the button STARTER beside the
mode selector to start the automatic process.
The ejection of the ferrule anyway must be carried out in manual operating mode.

6.2 Start the machine after a black out

Repeat all steps in section 6.1

6.3 Stop the machine in normal conditions

1. Finish the current automatic process if any.

2. Turn the operating mode selector to MAN.
3. From the main menu on the PC, digit F10 “Exit Windows”
4. If a ferrule has just been ejected, put the top roll in horizontal position (if the machine is
equipped with the accessory “top roll inclination”) and close the release.
5. If a piece is in the machine, lower the pinching roll paying attention that the plate is supported
by lateral rolls.
6. Push the STOP button.
7. If the machine is not to be used for long periods (2 days or weekly rest) turn the general switch
to pos. 0 (zero).

6.4 Stop in case of emergency

Push the hand button on the control station or the perimeter cable; the button will remain in its
position (pressed) while the cable, pushed or pulled, will have started the blocking device.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 22 / 58

6.5 Restart after anomaly

Repeat all steps in section 6.1

6.6 Restart after emergency

If the machine was stopped due to emergency, after the qualified personnel have identified and
solved the cause of emergency, to restart the machine please proceed as follows:
- Turn the hand button according to the arrow, then turn the key selector on the control station.
- Pull the blue knob on the safety limit switch at one end of the cable, then turn the key selector
as in the previous case.

6.7 Manual start in normal conditions

- Turn the general switch on the electrical gear box to pos. 1.

- Turn the key selector on the control station; after a few seconds the green light beside the key
will switch on.
- Use the single controls available on the control station; described in section 5.2.

6.8 Start the machine after a black out

Repeat all steps in section 6.7

6.9 Stop the machine in normal conditions

1. If a ferrule has just been ejected, put the top roll in horizontal position (if the machine is
equipped with the accessory “top roll inclination”) and close the release.
2. If a piece is in the machine, lower the pinching roll paying attention that the plate is supported
by lateral rolls.
3. Push the STOP button.
4. If the machine is not to be used for long periods (2 days or weekly rest) turn the general switch
to pos. 0 (zero).

6.10 Stop in case of emergency

Push the hand button on the control station or the perimeter cable; the button will remain in its
position (pressed) while the cable, pushed or pulled, will have started the blocking device.

6.11 Restart after anomaly

Repeat all steps in section 6.7.

6.12 Restart after emergency

If the machine was stopped due to emergency, after the qualified personnel have identified and
solved the cause of emergency, to restart the machine please proceed as follows:
- Turn the hand button according to the arrow, then turn the key selector on the control station.
- Pull the blue knob on the safety limit switch at one end of the cable, then turn the key selector
as in the previous case.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 23 / 58

6.13 POSITION OF THE OPERATORS DURING THE ACTIVITY OF THE MACHINE

During the manufacturing procedure the size of the plate to bend exceeds the size of the machine and
takes up an area, the dimensions of which vary according to the cylinder being produced.
IT IS ABSOLUTELY FORBIDDEN TO STAY OR TRANSIT IN THE AREAS A and B INDICATED
ON THE DIAGRAM BELOW, DURING ALL THE OPERATIONS SPECIFIED NEARBY.

If a bridge crane is used for plate loading, the customer will have to instruct correctly the personnel
about the risks relate to the use of this device and to block off the loading bay.
The control station must be positioned in a position accessible to the operator, allowing him to work in
a safe condition, and without interfering with the ferrule extraction.
During automatic operation, the operator can move voluntarily in the hazardous area. Since the
application of fixed shelters to this are is impossible, the customer has to give information and take
care of the training of the operators, according to the law in force.

A = Area taken up during the feed in and

bending of the plate.
B = Area, which is taken up during the
extraction of the work piece.
C = Area taken up by the operator during
the bending operations.

M = length of the plate

L = width of the plate

(top view)

THE MACHINE CAN BE USED BY ONE OPERATOR ONLY

The customer must inform the personnel that it is forbidden to remain in the area taken up by the
bending process, plate inlet and extraction. It is advisable to use proper warning signs and let the
machine operator or other suitable personnel supervise.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 24 / 58

6.14 PERSONAL PROTECTIVE EQUIPMENT

The use of personal protection garments and devices aimed to protect a specific part of your body
from all the risks related to the operation and maintenance of the machine must be enforced.

However, the use of personal protection equipment is not only limited to operating, maintenance and
cleaning but also in accordance to the environmental conditions.

- Protection of your hands: Leather protective gloves for handling the plates, which
usually have sharp corners and edges, and for standard
maintenance.
- Protection of your skin: Two-piece overalls, or anyway complete cover, with a long
sleeved jacket, for operating the machine and for
maintenance.
- Protection of your feet: Safety shoes with toughened toe caps to protect the feet
from crushing; safety shoes have to be worn also by
maintenance-engineers.
- Protection of your eyes: Glasses during blast cleaning, edge grinding, etc.
- Protection of your respiratory tract: Dust repelling mask to be used during blast cleaning, edge
grinding, etc..
- Protection of your hearing: Anti-noise Earplugs or headphones (The personal
protective equipment is recommended according to the
environment in which the operator works).

This list does not exclude the necessity of other personal protection equipments, according to
environmental conditions.

The personal protection equipments have to be in line with the current regulations.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 25 / 58

6.15 MOVEMENT OF THE PLATES

6.15.1 Feeding the plates by means of gantry crane

When the plates to be processed are particularly big and heavy (more than 30 Kg), it is necessary to
use the gantry crane.
The operator, by means of the gantry crane, inserts the plate and starts the rolls through the
commands on the control panel, until the plate is held by the rolls. The slings of the plate have to be
kept hooked for the whole execution of the pre-bending and they have to follow the plate during the
operation

Fase 1 Fase 2 ATTENTION: During

stages 2 or 3 the plate
could come out of the
central rolls and fall to
the floor.
Do not take off the
sling until the risk of
the plate coming out of
Fase 3 Fase 4 the central rolls is
over.

Do not allow any

movement of the
machine while
removing the slings.

6.15.2 Feeding the plates manually

When the plates to be processed are small and light (up to 30 Kg), they can be positioned manually
by the operator. The plate, supported by the operator, must be approached to the rolls from one edge
and pushed from the opposite edge until it is held by the rolls.

During the plate positioning, wear the personal protective equipment (protective
gloves and safety shoes).
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 26 / 58

6.16 WORK PIECE PRODUCTION

It is strictly forbidden to use the machine without the safety devices. Removal and/or
modification of the protection and safety devices fit to the machine is tampering and
exonerate the manufacturer from every and any responsibilities in case of accident.

WARNING: Before processing the plate,

check that the rolls are perfectly parallel
by using a feeler gauge.
The value you see in A must always be
equal to the value in B within some tenth
of millimetre (A ≥ B, never the
contrary); if the rolls are not parallel
please refer to the next paragraph.

The sequence described below is the most correct to obtain circular ferule, on the basis of the
experience of the manufacturer. Different procedures are possible, provided that they do not lead to
an incorrect use of the machine (please refer to chapter “Incorrect use of the bending machine”).

Plates with a length equal to or less than 1/3 of the maximum useful length of the machine must not
be bent in the middle of the rolls, but towards one of the extremities (release side or motor side).
WARNING: it is necessary to verify that working pressures are reduced, in order not to damage the
rolls or contribute to machine breaking.
Before inserting the plate in the machine, most of all in case of high thickness, the edges must be
ground and sharp edges eliminated.
Thick plates must always be heated before being inserted in the machine, to make the bending
process easier without damaging the rolls surface.
It is advisable to clean the plate surface; if necessary, sandblast them.

In order to create a cylinder, follow the steps below:

1) Lift the roll B so that you have a comparison

to align and square the plate with the
machine. Insert the plate and align it to the
roll.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 27 / 58

2) Lift roll C until the plate is pinched. The

pinching pressure depends on the size of the
machine, on the thickness and characteristics
of the plate and on the diameter of the
ferrule. It is anyway advisable not to exceed
50 bar.
Start rotation in order to bring the plate as
shown in the picture.
NOTE: The position of the plate must not
allow small rotations or inflections of the
central rolls during the next bending phase.
These inflections could cause the spillage of
the plate from the rolls. At the same time the
plate must not go too out from the rolls centre
line because the projected stretch is not bent.
3) Lower the bending roll B in order to free view
to the operator and to allow him to control
the previous alignment operation. Raise the
prebending roll A in order to form the first
prebending. It is better to raise gradually with
roll A and execute the rotation as per step 5.
The final position of roll A, that allows the
wanted radius, is repeatable only if the radius
has been obtained at the first attempt,
otherwise it has to be used as a guide for the
next plates but not as a correct setting value.

4) Execute the rotation till overcoming the

centre line of roll B and check the obtained
bending by templates.

5) Lower the prebending roll A so that they align

or simulate the loading deck, keeping the
plate pinched.

6) Raise the bending roll B so to support the

plate and recover the plate yield point
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 28 / 58

7) Start rotation till ¼ of the ferrule

circumference. If the machine is supplied with
lateral support, support it to the plate (without
forcing).

8) Start rotation till overcoming half of the

development. Then put in function the central
support (if available) in order to avoid wilting
and deformation of the ferrule under its own
weight. The support must drive the plate so
that, at the end of the rotation, the first end
(previously obtained) will not be taken again
by the rotating rolls.

9) Stop rotation when the plate loses the

support of roll A.

10) Raise the bending roll B so that you form the

second ferrule head; start rotation in order to
close the ferrule
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 29 / 58

11) Raise roll A and lower roll B so that you

centre and support the plate respect to roll D.

12) Sling the ferrule

13) Lower the pinching roll C
14) Extract the ferrule from the machine
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 30 / 58

6.17 ROLLS PARALLELISM

If after bending the first plates you find any difference in the diameter of the same work piece, this
may be caused by the parallelism of the rolls. In this case, carry out the following operations:

There are 2 potentiometers:

• MASTER : installed on the release side.
• SLAVE : installed on the opposite side.

Any adjustment of the roll parallelism must be made on SLAVE potentiometer according to the
following situations:

• The roll is higher on the release side:

Unscrew nut "C" of the potentiometer and rotate shaft "F" clockwise.
• The roll is higher on motors side:
Unscrew nut "C" of the potentiometer and rotate shaft "F" anticlockwise.

NOTE: The adjustment rotation of shaft "F" must be very small (half turns).
Tighten and check again.

6.18 PINCHING ROLL PARALLELISM

The adjustment of the pinching roll parallelism can be obtained with the following procedure:

1. Place two strips of plate, having exactly the same thickness, at each end of the pinching roll.
2. Raise the roll until pinching the two strips.
3. Read the values on the two pressure gauges: the pressure must be the same. If it isn’t, adjust
the linear potentiometer on the motor side according to the instructions given in the previous
paragraph.
4. Check again the pressure: if it is the same on both gauges, the parallelism is correct.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 31 / 58

6.19 EXECUTION OF A CONE

WARNING: During conical bending, make sure that the device on which the plate comes into
contact is constantly greased, in order to prevent damages to the cone rolling device.
The cone rolling device is however subject to normal wear, more or less rapid according to
the material to be processed and the pinching pressure applied.
It is considered a consumable item and periodically will need replacing. Contact our Service
Department on the numbers given in Chapter 1 of this manual.

CONICAL BENDING CAPACITY:

Pressing method : Max. conical thickness = 100% x nominal prebending thickness.

Rolling method : Max. conical thickness = 0,60 x nominal prebending thickness in any
case not over 20 mm plate thickness for material having Tensile Strength 400 N/mm² - Yield
Strenght 260 N/mm²-

PRESSING METHOD

The following operations allow bending a cone thicker than 20 mm up to 100% of the nominal
prebending capacity of the machine without stressing any part of the machine.

1) Trace the generator lines of the cone on

the plate.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 32 / 58

2) Insert the plate in the machine to make the first

prebending as usual.

3) Tilt the side rolls according to the cone angle

without pressing the plate.

4) Move the plate by means of a bridge crane in

order to have the first generator line traced on the
plate aligned to the top roll axe.

5) Go up with the side roll to deform the plate: go

up with the prebending roll if you are bending the
initial edge of the plate, or go up with the bending
roll if you are bending the central part of the plate.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 33 / 58

6) Go down with the side roll to release the

pressure on the plate.

7) By means of the bridge crane and with the aid

of the pinching roll, move the plate to have the
next generator line traced on the plate aligned to
the top roll axe.

8) Go up with the side roll to press the plate.

Repeat the steps 6-7-8 for each generator line until you reach the centre of the plate. Then move the
plate on the opposite end and repeat all the steps from 2 to 8 until you reach the centre of the plate.
Now you have the cone rolled.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 34 / 58

Check the cone symmetry and the bending radius by using a metallic or cardboard template; for the
correct measure you have to put the template on the plate in orthogonal position.

According to the cone angle/size and the plate thickness, you could need to repeat the process
several times reaching the final result gradually. Generally, the thicker the plate, the more the times
you have to repeat the process.

ROLLING METHOD

1) The plate must be cut to size (refer to the calculation formulas of the development).

2) Unbalance the lateral rolls. Entity of the unbalance: the unbalance is about 1 millimetre for
each degree of taper.
3) Make the prebending first from one side and then on the other side, reaching the final quotes
and making a little rotation (30-40 mm). During the prebending phases the pinching must be
not excessive, i.e. the plate must be pinched to a quote equal to the thickness of the plate.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 35 / 58

4) Lower the pinching roll and position the plate perfectly symmetric with the bent ends in the
centre of the machine and start bending. The lateral rolls must be little less unbalanced
respect to the pre-bending phase (of about 10%).

5) Help the plate to rotate keeping the small end against the pivot, using the pinching roll as
follows:
the tilting of the central roll is necessary when the rotation is difficult (the plate doesn’t
translate correctly or slides on the rolls). The tilting of the central roll has the opposite direction
respect to the unbalance of the lateral rolls and it is of a few millimetres.
After the tilting you make a slight pinching, (on the side of the bigger diameter) to be slacken
immediately as soon as the plate starts rotating, dragged from the rolls.
p.s.: this operation is necessary almost exclusively for the first bending. The plate already
formed as cone, usually, turns by itself. The contact between plate and pivot is recommended
during the whole operation.
6) In order to be sure about the correct process of rotation, draw some radius on the plate (along
the cones distance) so that you can follow the exact set of the cone under the central roll.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 36 / 58

7) After the first rotation and after you have inflicted the first yielding to the plate, you proceed
always from the centre, increasing the position of the lateral rolls and bending the two half
rotations till the closure of the wished diameter.
8) At the end of each bend, you have to check the symmetry of the cone and the obtained
bending. The bending is suggested with metallic or cardboard templates that must be kept in
orthogonal position respect to the plate.

9) The final result generally is reached in 4 or 5 bending. For bigger thickness, more bendings
are required.
10) Before finishing the cone, check the shape visually or using templates. If necessary, correct it
if it is too opened or closed from one end respect to the other, adjusting the unbalance of the
lateral rolls. This way you correct the mistake and you can finish the cone (or the sector of the
cone) in the desired shape.

NOTE: the smallest diameter of the ferrule must be such to allow the same ferrule enter the
machine.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 37 / 58

6.20 WORK PIECE EXTRACTION

Once the ferrule is completed, it has to be extracted

according to the following instructions:

- Make sure that the pinching roll has been

completely lowered to the end stroke.

- Turn the selector on the control panel to open the

release.

- Tilt the top roll through the proper command on

the control panel. The limit switch signalling the
release opening (SQ2, see section 4.1.1) must be
pressed to allow the roll tilting. If the machine is equipped with conical device, turn it of 180°.
NOTE: When the top roll is tilted, the machine can make no movement.

- Sling the ferrule to the lifting apparatus and extract it from the top roll.
- Bring the top roll back to its working position. The top roll lowering is stopped by the limit
switch on the cylinder (SQ3, see picture): when SQ3 is pressed, it allows the release closing.
WARNING: verify the exact alignment between roll and release. In case the roll is too high or
too low, adjust the limit switch SQ3.

SQ3
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 38 / 58

ATTENTION: During the ferrule extraction with gantry crane, the pinching roll must be open
only when the ferrule is correctly slung and no operators, other than crane operator, are in the
working area.
Also the bending machine operator, who is normally present in area B (see section 6.13) to
action the control station and check the whole process, will have to leave its place.

The release side and the floor must be free (with no obstacles) during the ferrule extraction.

Once the work piece has been extracted it has to

be laid on a flat surface with saddles. If it is laid
on the floor, it must be prevented from rolling
away by wedges or other suitable devices.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 39 / 58

7 OPERATING ANOMALIES
7.1 CONICAL DEFECT

CAUSE POSSIBLE SOLUTION

The central rolls are not parallel. Re-establish the parallelism between the
pinching roll and the top roll. In order to see the
effect of the correction, check on the
manometers put on the hydraulic cylinders that
the pinching pressure is the same on both.

7.2 ALIGNMENT DEFECT

CAUSE POSSIBILE SOLUTION

The plate has not been correctly aligned or it It is very difficult to recover this type of defect.
has not been cut with correct squaring. To try a correction you have to:
• lower the pinching roll;
• Unbalance lightly lateral rolls and pinching
roll.
• Make some complete ferrule rollings.
• Let the ferrule make several complete
rollings.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 40 / 58

7.3 BARREL DEFECT

CAUSE POSSIBLE SOLUTION

The thickness or the hardness of the plate is Check if the performance is the same when
greater than the perceived values for the roll using the correct thickness/hardness.
taper. Lay the edges of the tube against the lateral
rolls, then rotate more times forward and back.

If you have to bend another similar plate, it is

advisable to insert between top roll and plate a
thin steel band that simulates higher taper.

7.4 PINION DEFECT

CAUSE POSSIBLE SOLUTION

The plate thickness is too thin or the plate is of Try the correction increasing the pressure of
mild material respect to the values foreseen for the pinching roll (exceeding with the pinching
the rolls taper. you can obtain a ferrule with irregular edge).
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 41 / 58

7.5 IRREGULAR EDGE

CAUSE POSSIBLE SOLUTION

The pinching pressure is excessive. Reduce the pinching pressure. To avoid the
inconvenient rotate repeatedly the tube in the
machine.

7.6 STRAIGHT EDGE TOO LONG

CAUSE POSSIBLE SOLUTION

The flat end can be up to 2,5 times the Try to solve the problem by re rolling the
thickness plate. cylinder in the machine after the same has
If it exceeds this value it means that after been welded and rotate it repeatedly.
squaring the plate in the rolls, it has not
DURING THIS TYPE OF CORRECTION THE
been moved back far enough.
WELDED SEAM MUST BE DRESSED BY
GRINDING TO PREVENT DAMAGE TO THE
ROLL SURFACE.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 42 / 58

7.7 EDGE TOO CLOSED

CAUSE POSSIBLE SOLUTION

During the pre-bending the top roll was too It is not possible to recover this problem within
high. the normal use of the machine.
POSSIBLE INTRODUCTION OF LEVERS OR
WEDGES BETWEEN ROLL AND PLATE TO
FORCE OPEN THE PART ARE NOT
SUGGESTED AND THEY ARE AT THE RISK
OF THE OPERATOR
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 43 / 58

8 INCORRECT USE OF THE BENDING MACHINE

The actions described below, which obviously do not cover the whole range of possible incorrect uses
of the machine, have to be considered as “ABSOLUTELY FORBIDDEN”.

8.1 MACHINE TURNED OFF WITH THE TOP ROLL TILTED

The machine can NEVER be turned off with the top roll tilted, in order no to keep the hydraulic circuit
in pressure for a long time. Before turning the machine off, bring the top roll in horizontal position.

8.2 OPENING OF THE PINCHING ROLL

It is absolutely forbidden to open the

pinching roll while the ferrule is being
slung for extraction.

In case the ferrule can’t be slung from the floor, due to its size, it is care and responsibility of the
customer to predispose a proper slinging procedure, respecting the safety requirements of the law in
force.

Climbing on the machine is strongly forbidden!

 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 44 / 58

8.3 ROLLING OF PROFILES BETWEEN THE ROLLS

This is to avoid: the surface of the hardened rolls can be seriously damaged.

To bend profiles, it is necessary to

use suitable machinery manufactured
for that sole purpose.

8.4 GRINDING OF THE PLATE

Avoid grinding of the plate on the

machine both for the hardness test
and for the removal of burrs or for
bevelling.

8.5 WELDING OF THE FERRULE ON THE MACHINE

Do not weld the ferrule on the machine. FACCIN denies liabilities in case of damage caused by the
machine because of welding of ferrules on the machine.

8.6 ALTERATION OF THE PERFORMANCE LIMITS

The machine parameters such as speed, thrust, and torque are determined by modulating pressure
valves and are calibrated during the testing by FACCIN qualified personnel.
The seal of modulating valves of thrust or torque mustn’t be tampered for any reason. Seal
tampering leads to annulment of the warranty.

8.7 REMOVAL OF THE MEMORY CARD

The incautious removal of the memory card can cause the loss of all the data of the machine and the
programs saved, therefore the memory card mustn't ABSOLUTELY be removed without the
authorization of the Technical Service FACCIN.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 45 / 58

9 MAINTENANCE

The bending machine 4HEL requires a few and specific periodical maintenance interventions.

Maintenance can be carried out by:

- internal qualified personnel (ordinary maintenance)
- Technical Assistance personnel sent by the manufacturer (extraordinary maintenance).

Ordinary maintenance means cleaning, check of the oil levels, replacement of consumables and set-
up.

Extraordinary maintenance is required in the following cases:

- mechanical or electrical breakdown
- repairs of broken parts of the machine
- when the frequency of problems increase
- when, during maintenance, deterioration of the structures or of the mechanisms are found
- at least once a year (depending on the operation frequency and condition of the machine), to
verify the functionality and residual life of the equipments
- when the equipment has reached the limit that it had been intended or anyway ten years have
elapsed since installation and first operation.

Never carry out interventions for which you have not been authorized

FACCIN S.r.l. denies liabilities for any risk for the personnel’s safety and for damage to the
4HEL that are brought about by the incorrect compliance with the instructions of this manual.

During any operation of maintenance, unmistakable warning signs must be put on the machine and
close to the main switch on the electric board, bearing the following indication:

DO NOT USE:
MACHINE UNDER MAINTENANCE!

WARNING: at the end of the maintenance, verify that:

• electric and hydraulic connections have been restored,
• no tool was left inside the machine, and
• the safety and emergency devices are perfectly working.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 46 / 58

9.1 ORDINARY MAINTENANCE

In order to keep the machine functioning and to avoid damage and inconvenience, the machine needs
periodical checks and consequently maintenance interventions, as indicated in the «TABLE OF THE
PERIODICAL CHECKS AND INTERVENTIONS»; all the checks have to be carried out as
recommended by the manufacturer.
The intervals described in the table of the periodical checks and interventions are calculated
considering the machine works 8 hours a day, 5 days a week: if the machine works with different
rhythms, the frequency will have to be adjusted.

WARNING: in the event these checks are not carried out, the machine might encounter break down
and early deterioration. It is recommended to respect the prescriptions of the manufacturer.
Do not use flammable liquids to clean the machine.
Do not use compressed air to clean the rolls, as the eventual slag might be pusher into the gearings
and cause breakdown. Do not use water or other liquids; if necessary, dry the rolls surface to avoid
rust.

Before any maintenance intervention, disconnect the machine from the electric
source.

PERIODICAL CHECKS AND INTERVENTIONS FREQUENCY

1. Clean the rolls surface.
Slag or particles on the rolls represent the
main cause of breakdowns or early
deterioration of the internal components Daily
(bearings, slides, etc.). It is therefore
necessary to clean the rolls surface daily
with hard bristle brushes or dry rags.

2. Check the oil level in the tank through the

oil level gauge OPTIMAL LEVEL

During the normal functioning of the machine

the level of the oil has not to go under the red Daily
line on the dip stick (minimum level). If
necessary, top up using one of the MINIMUM LEVEL
recommended oils (see table in par. 9.2.1).

3. Lubrication
If there is a lubrication pump (1), use it every
day; otherwise lubricate the parts of the Daily
machine by means of the special greasers (2)
on the housing.
Bearings:
Lubricate the bearings with grease type EP2
every 15 days. 15 days

4. Check the tightening of the screws on the Monthly

 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 47 / 58

gear boxes
For the driving torque please refer to the
table in Chapter ANNEXES.

5. Clean the runners of the rolls (1) and the

release (2)
Daily
Clean the runners of the rolls and the release
with rags and then lubricate.

First 50 hours of
6. Check the tightening of the flexible hoses
operation, then
Monthly

7. Clean the chromium-plated bars of the

pistons (1)
Too much dirt could damage the inner seals Weekly
and bring about serious oil filtrations
Clean the poles of the potentiometers (2)

8. Change the gear box oil

For the oil replacement in the gearbox, follow
this procedure: First 100 - 150
• Unscrew plug 3 off and remove the oil; hours of operation
• Replace plug 3 on the gear box. Remove
plug 1 and fill with the correct oil (see proper 2500 - 3000
table in the next pages) to the correct level 2; hours of operation
• Close the box gear with plug 1

9. Clean the air inlet (1) of the electrical

motor
Monthly
Remove the cover and clean the air inlet by
means of compressed air.

10.Change oil in the tank

The instructions for the correct execution of
this procedure are explained in the following 2000 hours of
paragraph (9.2). operation
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 48 / 58

11. Filter cartridge replacement

To change the cartridge of the filter carry out the
following:
• remove lid 1 of the filter
• take out the cartridge 2
• Insert a new cartridge
• replace lid 1 2000 hours of
If a replacement of the cartridge is necessary operation
but no new cartridge is available, a temporary (or when the light –
solution might be cleaning the surface of the optional- is on)
cartridge.
WARNING: Pay attention not to damage the
cartridge and not to pollute the oil by introducing
objects or other liquids, this may cause
breakdown of the machine.

TABLE OF PERIODICAL MAUINTENANCE FREQUENCY

OPERATION N° Day Week Month Year
CLEAN THE ROLLS 1 •
CHECK THE OIL LEVEL 2 •
LUBRICATION 3 • Bearings:
15 days
CHECK THE TIGHTENING OF THE 4 •
SCREWS ON THE GEARBOXES
CLEAN RUNNERS OF THE ROLLS AND 5 •
THE RELEASE
CHECK THE TIGHTENING OF FLEXIBLE 6 •
HOSES
CLEAN THE CHROMIUM PLATED BARS 7 •
OF PISTONS AND POTENTIOMETERS

CHANGE THE OIL OF THE GEARBOXES 8 2500-3000

hours of
operation
CLEAN THE AIR INLET OF THE 9 •
ELECTRICAL MOTOR
CHANGE THE OIL IN THE TANK 10 2000 hours of
operation
CHANGE THE FILTER CARTRIDGE 11 2000 hours of
operation
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 49 / 58

9.2 OIL TANK AND HYDRAULIC UNIT

TANK

The tank is usually positioned under the rolls. Depending on the arrangement of the machine, it might
be installed on a separate unit (see picture below).
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 50 / 58

On the tank you can find:

1) Filling plug
2) Optical level 1
3) Return filter. 3

For the periodical oil replacement, follow

this procedure:
a) Close the taps (A, picture 2) that
connect the tank to the hydraulic 2
pump.
b) Unscrew the filling plug (1) and
remove the oil with the aid of a
4
pump.
c) Unscrew the magnetic plug (4) to
verify that there is no slag. If
necessary, clean the bottom and
replace the plug. (picture 1)
d) Fill the tank until reaching ¾ of
the optical level (2).

OPTIMAL LEVEL

(picture 2)
WARNING: Use only the types of
oil indicated in the proper table in
the next page.
e) Before starting the machine, verify
that the taps (A, picture 2) are
open.
IMPORTANT: the oil removed must be treated as
special waste, according to the law in force.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 51 / 58

9.2.1 TABLE OF THE RECOMMENDED OILS

The following lubricants (or equivalent) are recommended:
SPEED REDUCERS HYDRAULIC UNIT GREASE PLANT
(FILTERED 10 µ)
Mark Class C (ISO CC 150) Class H (ISO HV 46) * Class X (ISO XM 0)

BLASIA 150 ARNICA 46 GR MU EP 0

ENERGOL GR-XP 150 BARTRAN HV 46 GREASE LTX0

GREASE LTX0-EP

MOBIL GEAR 629 MOBIL DTE 15 MOBIL LUX EP 0

GOYA 150 HAENDEL 46 REMBRANDT EP 0

OMALA OIL 150 TELLUS OEL T46 ALVANIA EP 0

HIDROL HV46 SUPER GREASE EP 0

MEROPA 150 RANDO OIL HD 46 MULTIFAK EP0

MARFAK 0

CARTER EP 150 EQUIVIS ZS 46 MULTIS EP 0

MULTIS 0

REDUCTELF SP 150 HYDRELF DS 46 ROLEXA 0

EPEXA 0

SPARTAN EP 150 UNIVIS N46 BEACON EP 0

ALPHA SP 150 HYSPIN AWH 46 SPHEEROL APT 0

SPHEEROL EPL 0

RIPRESS EP 150 ANTARES HLP 46

* with room temperature over 40°C, use oil type ISO HV 68.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 52 / 58

9.2.2 Layout of the lubrication points

Please refer to the hard copy of the manual delivered with the machine.

9.3 MAINTENANCE OF THE ELECTRICAL INSTALLATION

In case it is necessary to replace parts of the
electrical installation, it is recommended to:
• Mount components that have the breaking
capacity indicated in the scheme;
• Do not change the thermal relays (find out
the causes ;)
• Always check the efficiency of the
grounding (earth) connection.

Remember that the parts replacement and

the connections reset must be carried out
by qualified personnel.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 53 / 58

10 PROTECTION AND EMERGENCY DEVICES

The machine is provided with devices installed for the protection of the operators, these included:
- Boxes containing electrical equipment that are always locked (the key is kept by the
maintenance-engineer). The cables of auxiliary controls are protected by flexible anti-crush
coverings.
- All the machine controls are detent controls, then their action stops when the control (button,
joystick, selector, etc.) is released.
- Push-button for the emergency stop on the control panel.

The red and yellow emergency push-button

(located in the lower right angle of the control
station) is a self latching type and to restart the
push-button must be reset.

TO REGENERATE THE MACHINE FUNCTION,

ROTATE THE HEAD PUSH-BUTTON
CLOCKWISE (AS INDICATED BY THE
ARROWS).

- Motors and transmission gears within the steel structure are protected by integral fixed
shelters.
- Where the machine have moving parts that are accessible but cannot be protected, a
perimeter cable, electrically connected to the off switch has been fitted. This device works if
the cable is pulled or pushed, and can be easily reached by the hand or the leg of the
operator. The distance from the machine varies according to the size and the shape of the
machine itself; however, it is positioned so that no one can stay between the cable and the
structure of the machine.

Inextensible cable: as it is touched, the machine is

immediately stopped.

DO NOT OPERATE ON THE MACHINE WITHOUT THE PROTECTION AND EMERGECY

DEVICES.
The removal and/or modification of the safety and/or protection devices supplied with
the machine is tampering and relieves the manufacturer from any responsibility.
The correct functioning of emergency devices must be verified each time the machine
is operated.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 54 / 58

- The machine is provided with the following signs indicating the risks and the obligations of the
operators.

Danger of entangling the hands between the rolls.

The sign is positioned on the housing of the machine on both the feeding
side and the back side.

Danger of crashing and shearing hands

The sign is positioned on the drop end release

Voltage of 400 V
The sign is positioned on the cover of the electrical box and on the control
station to signal the presence of live parts with the risk of electric shock. The
signs have to indicate the value of the working voltage.

Do not remove the fixed covers from the machine.

The sign is positioned on the removable covers protecting the speed
planetary gears.

10.1 PROHIBITIONS AND OBLIGATIONS FOR THE OPERATOR’S SAFETY

PROHIBITED! Presence of the operator on the rolls
PROHIBITED! to check the quality of the bending by walking on the rolls, even if the machine is
turned off.

It is possible to check the form of the work

piece through templates from outside the
machine, with the machine off.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 55 / 58

It is absolutely forbidden to stand on the plate

when in the machine.

Do not stay under a plate that is being

processed (during both pre-bending and
bending) because it could suddenly slip out of
prebending process the rolls and injure the people underneath.

bending process

OBLIGATION! Beyond the elementary precautions which constantly grant your own safety, every
operator has always to observe what recommended in this paragraph.
OBLIGATION! In case this manual is not available, or for any further information about the safety
and the correct use of the machine, contact exclusively the person responsible for
safety.
OBLIGATION! When you receive a new copy of the manual, verify the completeness of the safety
regulations.
OBLIGATION! FACCIN S.r.l. denies liability for damages brought about by the wrong interpretation
of the content of the operating manual and not being able to read the manual due to
its deterioration or incompleteness.
OBLIGATION! The operators have to be qualified, reliable and properly trained to use the machine,
skilled and authorized for the performance of the job, as required by the person in
charge, in particular concerning the following points:
- the safety of the operators and of the other workers
- the correct functioning and utilization of the machine
- the ordinary maintenance
OBLIGATION! Any intervention on the electrical and hydraulic system of each unit of the machine
must be carried out exclusively by qualified personnel who have been authorized by
the person in charge for the safety.
PROHIBITION! Non qualified personnel or staff that have not been authorized to carry out electrical
repairs cannot tamper or try to repair the electrical devices of the machine and its
equipment.
PROHIBITION!: Do not carry out interventions that do not fall within your professional competence,
that is defined by specific written authorization by the person in charge of safety, for
the machine and its equipment, in order not to compromise yours and the other’s
safety.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 56 / 58

OBLIGATION!: Always wear accident prevention garments provided with adherent cuffs, approved
by the person in charge of safety, in order not to get entangled between the moving
parts;
PROHIBITION!: Do not wear garments that are too large, that are too wide or too long sleeves, with
unbuttoned cuffs, with collars, fluttering frills or corners, ties or scarves;
PROHIBITION! Do not wear rings, bracelets, bands, collars and pendants;
PROHIBITION! Do not wear your hair too long, or at least wear it in a bun protected by special caps;
PROHIBITION!: Do not work on the machine in case of imperfect personal efficiency, due to
tiredness, disease, abuse of stimulating/sedative substances, or medicines which
can bring about loss of balance or sleeplessness.
PROHIBITION AND OBLIGATION!: Do not smoke near the machine, never throw cigarettes, cigars
or matches etc. that are not completely extinguished. Use special ashtrays
positioned at a safe distance from the machine.
PROHIBITION AND OBLIGATION!: Do not let wounds, no matter how slight, come in contact with
parts of the machine, dirty rags and other objects; do not keep your eyes too close
to the parts in motion: if this is essential, use special protective glasses, approved by
the person in charge of safety.
PROHIBITION! Do not try to stop or to slow the moving parts with your hands, or any other part of
your body or with any object. Do always avoid any physical contact with moving
parts.
PROHIBITION! Do not carry out maintenance while the machine is on: in particular, never lubricate
or grease manually the parts while moving and never access or operate with live
parts.
OBLIGATION!: Before carrying out any servicing or maintenance operation, always turn the
machine off as recommended in this manual, in order to avoid any danger.
PROHIBITION!: Do not forget to take away all tools, instruments etc. from each unit after use.
PROHIBITION! Do not remove or damage any protective devices from the machine i.e. covers,
perimeter cable, emergency button, key switch, etc.: the machine should not be
allowed to operate without any all these devices being in place and working.
OBLIGATION!: In the event of a malfunction or a serious failure, which could be dangerous for the
personnel, immediately push the red head emergency pushbutton on the control
station and then, completely switch off the machine as instructed, and finally report
immediately the situation to the person in charge.
OBLIGATION!: The machine can be connected to the net and switched on again only once the
malfunction or the failure has been removed by the qualified and authorized
personnel and once the person in charge has given his authorization.
PROHIBITION! In case the machine has to be moved or lifted both during the installation and
afterwards, no one must remain in or near the area involved in the movement, in
order to grant personal safety.
OBLIGATION! Always wear the special protection garments established by the person in charge of
the safety, in order to avoid exposing yourself to any risk.
OBLIGATION!: Before wearing protective gloves and using these for any operation on the machine,
switch the machine completely off as described in this manual, in order to avoid
exposing yourself to any risk of mechanical nature.
OBLIGATION! Respect all the signs positioned in the working area of the machine placed by the
person in charge of safety.
OBLIGATION!: The person responsible for the cleaning of the plant where the machine is situated is
required to observe all the regulations established by the person in charge of safety,
in particular the warnings related to the cleaning of the floor, to the employment of
the indicated products and to the necessary frequency of cleaning.
OBLIGATION!: Before using the machine, carry out all the periodical checks and interventions
described in paragraph ORDINARY MAINTENANCE.
PROHIBITION!: Never try to use the machine for operations different from the technical features
described in this manual for use.
PROHIBITION!: Never insert any object inside the electrical cabinet, in particular when the machine
is working.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 57 / 58

11 DECOMMISSIONING OF THE MACHINE

11.1 INSTRUCTIONS FOR DECOMMISSIONING

If the machine has to be stopped for long time, it’s necessary to disconnect it from the power supply.
It is recommended the hydraulic power unit has the oil drained paying attention that there is no dust,
humidity or other substances that can damage the hydraulic power unit components.
Oil and protect the cylinder shaft and all the machine runners.
Protect the machine, the top part included, with cardboard.
The restarting of the machine after a long period of inactivity must be carried out following carefully
ALL the instructions specified in this manual.

11.2 DISASSEMBLY OF THE MACHINE FOR ABANDONING

In case the machine 4HEL has to be disassembled, contact exclusively the Technical Assistance at
FACCIN S.r.l.

In case the machine has to be scrapped, you must follow the laws in force in the country where the
machine operates. Afterwards, the whole scrap must be taken exclusively to a Company or an
Agency qualified and authorized by the appropriate authorities for the disposal of the materials, in
particular:
- varnished, galvanized, burnished or materials having undergone other specific heat or superficial
treatments on ferrous metals;
- varnished nonferrous metals, and metals that have undergone other superficial treatments;
- plastics;
- electric cables, motors, electric and electronic components;
- dirty rags (for oil or grease);

It is recommended that the oil from the tank of the hydraulic unit is drained, eliminating the traces of
lubrication grease in the speed planetary gears, cylinders, pipes, pump, valves, and the lubrication
grease; all these materials have to be disposed as special waste.
 4 rolls bending machine

The transfer and/or copy of the content of this document is forbidden Page 58 / 58

12 ANNEXES

The machine is delivered to the customer with the following documentation, attached to the manual:

- Description of the accessories

- Driving torque tables
- Technical data of the machine
- Technical data of the main components
- Assembly drawings and emergency devices layout
- Hydraulic diagram and components
- Electric diagram and components
- CE declaration of conformity
- Declaration of the noise level

Please refer to the hard copy of the manual delivered with the machine.