Master Plate Roll 2nd Ediz 6rev ENG

INSTRUCTION MANUAL Date:.10.
2020
INSTRUCTION MANUAL
INSTALLATION – USE – MAINTENANCE
ROCCIA S.r.l. Via dell'artigianato, 30 - 12040 S. Albano Stura (CN) Italy -

VAT code 03384510040
Date: 10.2020 Edition: 2 Revision: 6
Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 1 of 87

INSTRUCTION MANUAL Date:.10.2020
TABLE OF CONTENTS
1.0 GENERAL INFORMATION ............................................................................................. 5
1.1 IDENTIFICATION DATA OF THE PRODUCER .................................................................. 5
1.2 CERTIFICATION ................................................................................................................ 6
1.3 WARRANTY ...................................................................................................................... 6
1.4 STRUCTURE OF THE MANUAL ......................................................................................... 7
1.5 ARRANGEMENTS TO TO BE PROVIDED BY THE USER ................................................... 7
1.6 AIM AND CONTENT ........................................................................................................ 8
1.7 ADDRESSEES .................................................................................................................... 8
1.8 CONSERVATION.............................................................................................................. 8
1.0 DESCRIPTION OF THE MACHINE ....................................................................................... 9
2.1 OPERATING PRINCIPLES ................................................................................................. 9
2.2 MAIN COMPONENTS ...................................................................................................... 9
2.3 ENVIRONMENTAL CONDITIONS .................................................................................... 9
2.4 LIGHTING........................................................................................................................ 10
2.5 VIBRATIONS ................................................................................................................... 10
2.6 NOISE EMISSIONS .......................................................................................................... 10
2.7 TECHNICAL DATA ......................................................................................................... 11
2.8 STANDARDS ................................................................................................................... 11
2.9 SUPPLIES ON DEMAND ................................................................................................. 11
2.9.1 CENTRAL SUPPORT...............................................................................................................................11
2.9.2 LATERAL SUPPORT ...............................................................................................................................12
2.9.3 INTERCHANGEABLE TOP ROLLER ......................................................................................................15
2.9.4 FEEDING TABLE .....................................................................................................................................16
2.9.5 VACUUM CONVEYOR ........................................................................................................................16
2.9.6 EJECTOR ................................................................................................................................................17
2.9.8 RADIUS MEASURING TOOL .................................................................................................................18
2.9.9 SHELL CALIBRATION DEVICE ..............................................................................................................18
2.10 ELECTROMAGNETIC ENVIRONMENT ....................................................................... 19
3.0 SECURITY.................................................................................................................................. 20
3.1 GENERAL INSTRUCTIONS .............................................................................................. 20
3.2 FUNCTION OF THE MACHINE ....................................................................................... 20
3.3 CONTRAINDICATIONS .................................................................................................. 21
3.4 DANGEROUS ZONES..................................................................................................... 22
3.5 PROTECTION DEVICES .................................................................................................. 22
3.6 STOP FUNCTIONS .......................................................................................................... 23
3.7 SAFE WORKING PROCEDURES .................................................................................... 26

3.8 FURTHER RISKS ............................................................................................................... 28

3.9 MACHINE LABELS .......................................................................................................... 29
4.INSTALLATION ............................................................................................................................ 31
4.1 UPLIFTING ....................................................................................................................... 31
4.2 TRANSPORTATION AND MOVEMENT .......................................................................... 32
4.2.1 TRANSPORTATION ................................................................................................................................32
4.2.2 UNLOADING AND MOVEMENT .........................................................................................................32
4.2.3 OUTPUT ..................................................................................................................................................33
4.3 STOCKING AND SHUTDOWN ....................................................................................... 33
4.4 PREPARATIONS .............................................................................................................. 34
4.5 ASSEMBLING .................................................................................................................. 35
4.6 PLACING ........................................................................................................................ 35
4.7 FIXING AND LEVELING OF THE MACHINE................................................................... 37
4.8 CONNECTION ............................................................................................................... 38
4.9 PRELIMINAR CONTROLS ............................................................................................... 39
4.9.1 PLANETARY GEAR BOX .......................................................................................................................39
4.9.2 HYDRAULIC POWER UNIT ....................................................................................................................39
4.10 SETTING AND VERIFICATIONS................................................................................... 40
5.FUNCTIONING ........................................................................................................................... 41
5.1 AUTHORIZED PERSONNEL ............................................................................................. 41
5.2 CONTROL PANEL .......................................................................................................... 41
5.3 START-UP AND USE ............................................................................................................. 41
5.3.1 TURN-ON................................................................................................................................................41
5.3.2 WORKING SPEED..................................................................................................................................42
5.4 FUNCTIONING MODES ................................................................................................. 43
5.4.1 MANUAL CYCLE ...................................................................................................................................43
5.4.2 AUTOMATIC CYCLE .............................................................................................................................69
5.5 COMPLETION OF WORK .............................................................................................. 69
6.0 MAINTENANCE ...................................................................................................................... 70
6.1 MAINTENANCE OPERATIONS ...................................................................................... 70
6.2 MAINTENANCE STATUS ................................................................................................. 70
6.3 MACHINE INSULATION ...................................................................................................... 70
6.4 SPECIAL PRECAUTIONS ................................................................................................ 71
6.5 CLEANING ..................................................................................................................... 71
6.6 ORDINARY MAINTENANCE .......................................................................................... 72
6.7 EXTRAORDINARY MAINTENANCE..................................................................................... 75
7.0 DIAGNOSTICS ........................................................................................................................ 76
7.1 ALARMS AND FAULTS ................................................................................................... 76

7.2 TROUBLESHOOTING ...................................................................................................... 76

7.3 REQUEST OF SUPPORT .................................................................................................. 77
8.0 REPLACEMENT PARTS ........................................................................................................... 78
8.1 SPARE PART LIST............................................................................................................. 78
8.2 ORDERING REPLACEMENT PARTS ............................................................................... 78
9.0 INDIVIDUAL PROTECTION DEVICES .................................................................................. 79
9.1 PPE IDENTIFICATION...................................................................................................... 79
9.1.1 PPE FOR THE ORDINARY USE OF THE MACHINE ..............................................................................79
9.1.2 PPE FOR MAINTENANCE OPERATIONS .............................................................................................80
10.0 PERSONNEL TRAINING ....................................................................................................... 81

10.1 TRAINING OF THE OPERATIVE PERSONNEL................................................................ 81
11.0 DEMOLITION ......................................................................................................................... 82
11.1 DISPOSAL OF PROCESSING WASTE............................................................................ 82
11.2 DEMOLITION OF THE MACHINE ............................................................................... 82
APPENDIX A................................................................................................................................... 83
APPENDIX B ................................................................................................................................... 84
APPENDIX C .................................................................................................................................. 85
APPENDIX D ............................................................................................................................. 87

INSTRUCTION MANUAL Date: 12.2016
1.0 GENERAL INFORMATION
1.1 IDENTIFICATION DATA OF THE PRODUCER
COMPANY NAME
ROCCIA S.r.l.
SEAT Via dell’artigianato, 30
12040 S.ALBANO STURA

(CN) ITALY
TEL. 0039 0172.474388 FAX. 0039 0172.474324
CEO ROCCIA Gabriele
Born in Savigliano (CN), Italy on the 18.08.1989
T.C. RCC GRL 89M18 I470B
VAT CODE 03384510040
TAX CODE 03384510040
E-MAIL info@rocciasrl.com

1.2 CERTIFICATION
The machine was realized in accordance with the applicable Community

Directives in force at the time of its placing on the market. For detailed
explanations, see the declaration of conformity (APPENDIX A) at the end of the
present manual.
1.3 WARRANTY
The warranty on the components of the machine will expire on the date
mentioned on the tax documentation delivered with the machine. It includes:
- 12 months on the mechanical part

- 12 months on the electric, electronic and motor part.
It is obligatory to show the tax documentation to ask for the application of the
warranty.
The warranty consists in the substitution of manifestly defective pieces. New pieces
will be delivered only if it can be ascertained that the breakage derived from
material or manufacturing defects. The warranty includes only defective pieces
and does not cover the costs of the delivery, nor the call, travel and work of the
technicians.
The warranty will not cover damages caused to the machine by the following:
• transport and/or movement (if taken care of by somebody different from the
producer ROCCIA S.r.l.);
• wrong or improper use of the machine;
• lack of the necessary maintenance, as explained by the present manual
• damages and/or breakdowns not deriving from defective parts;
• changes made without the written authorization of the producer;
• small parts exposed to normal wear.
In case of problems, please ask for intervention by fax or by email and state clearly
the serial number of the machine.
Fax: 0039 0172 474324

E-mail: service@rocciasrl.com

1.4 STRUCTURE OF THE MANUAL
Users are kindly asked to read very carefully the following

instructions, because a correct preparation, installation
and use of the machine are essential to make it work in a
regular and, above all, safe way. It is strongly
recommended, therefore, to read the whole
documentation concerning the product you bought
(hydraulic and wiring diagram etc.)
1.5 ARRANGEMENTS TO TO BE PROVIDED BY THE USER
The user must provide for the following arrangements:

CASE 1
Fastening of the machine on the floor at the points indicated by paragraph 4.7 of
the present manual.
CASE 2
Realization of the base supporting the machine: the characteristics of the base are
explained by paragraph 4.4 of the present manual.
Realization of the demarcation lines to delimit the dangerous zone potentially

occupied by metal plate. The lines must be drawn according to the individual
characteristics of the production site.
Moreover, it is necessary to arrange for the connection to the power supply. This
work must be taken care of by qualified personnel with good knowledge of the
process and of the risks deriving from electricity. The method of execution of this
process is explained by paragraph 4.8 of the present manual.

1.6 AIM AND CONTENT
This manual aims to provide the user with all the necessary information to use the
machine in the most correct, independent and safe way possible. It includes
information concerning the technical aspects of the machine, its functioning, its
maintenance and its security.
Before doing any actions on the machine, operators and technicians should
carefully read the instructions of the present manual. In case of doubts about the
correct interpretation of the instructions, please contact the producer indicated in
the paragraph 1.1 of the manual, in order to receive the necessary explanations.
1.7 ADDRESSEES
This manual was created for the operator of the machine as well as for the
maintenance technicians. People in charge of the transport of the machine
should not do any of the operations reserved to the service technicians or to
qualified personnel.
1.8 CONSERVATION
This use and maintenance manual must be printed out and kept at a close
distance from the machine, in a suitable container protecting it from liquids, dust
and whatever could possibly make it difficult to read. In case the document is lost
or destroyed, please ask the producer for another copy (paragraph 1.1).

1.0 DESCRIPTION OF THE MACHINE
2.1 OPERATING PRINCIPLES
The function of this machine is to bend mechanically metal plate in order to give it
a precise radius of curvature. The material passes through parallel-shaft rolls
following a certain trajectory which determines its radius of curvature, depending
on the mutual position of the rolls.
The work area should be determined according to the size of the metal plate to
be bent.
The manufacturing process consists in the following steps:
- loading of the rough material on the machine
- alignment and blocking of the material between the rolls
- realization of the radius of curvature
- unblocking of the material and opening of the rolls
- unloading and extraction of the processed material from the machine
THE MACHINE MUST BE USED BY ONE OPERATOR ONLY!

The presence of two operators is allowed only during the phases
of loading and unloading of the material. Before starting any
other operation, the operator in charge of the activation of the
machine must verify the absence of other workers in the area.
IT IS STRICTLY FORBIDDEN TO DO ANY WELDING WORK ON THE

MACHINE, IF NOT IN ACCORDANCE WITH THE INSTRUCTIONS
GIVEN IN PARAGRAPH 2.10
2.2 MAIN COMPONENTS
The main parts composing the machine are:

- body of the machine
- control panel
2.3 ENVIRONMENTAL CONDITIONS
The machine does not require a particular environment, although it is necessary to

use it only in an area protected from weather conditions. Verify that the
supporting floor is sufficiently solid and level with regard to the weight of the
material, in order to avoid any stability problems. Operate the machine only under
adequate daylight or artificial light conditions and with a correct aeration. The

temperature of the environment should range from min -5°C to max +40°C to
guarantee a safe and effective functioning.
Always make sure the machine is protected from weather

events!
The machine has an insulation grade IP 54, so as to keep it
protected from the dust and light water jets.
2.4 LIGHTING
The work area hosting the machine must have a good visibility in all its parts, in
accordance with the applicable norms.
In case of use in a pit, the machine offers own lighting in the engine area and in
the hydraulic power unit. A correct lighting should be between 200and 300 LUX.
2.5 VIBRATIONS
The functioning of the machine does not produce any vibration that could result
dangerous for the personnel. In no occasion the operator will be exposed to
“hand-arm” or “whole boy” vibrations.
2.6 NOISE EMISSIONS
The machine was designed and realized in order to reduce noise emissions at their
source. The emission level Leq(A) is:
CASE 1 (HR4W 3120N )

lower than 85 dB(A).
CASE 2 (HR4W 306A, HR4W 332E, HR4W 126P )

lower than 80 dB(A).
NOTE
The noise values here presented are levels of emission: they are not necessarily
levels of safety. Although emission and exposition levels are related, the former
cannot be considered as a reliable value when deciding whether to implement
further safety measures.
The actual exposition level of the manpower is determined by the following
factors: duration of the exposition, characteristics of the work space and other
noise sources (number of machines, close by work processes etc.)
Nevertheless, the above mentioned information will allow the users of the machine
to better evaluate the dangers they are exposed to.

2.7 TECHNICAL DATA
The technical features of the machine are explained in detail in the "APPNDIX B" at
the end of the present manual.
2.8 STANDARDS
The equipment includes:

- machine
- instruction manual
- solid CE marking on the machine
- declaration of CE conformity
2.9 SUPPLIES ON DEMAND
At the customer's request, it is possible to receive the following components:
2.9.1 CENTRAL SUPPORT
The central support is already mounted on the machine when possible. In case it is
delivered separately, please follow these simple instructions:
1) Lift the bridge and block it on the upper part with a band.
2) Lay the bridge on the top part of the machine, as shown in the following
picture. Make sure the fixing plates are aligned with the fixing plates of the
machine.
3) Fix it with screws (delivered with the rest of the machine equipment)
4) Connect the two oil tubes, as shown in the following picture.

5) In order to lift the support, operate the CONTROLLER lever on the control panel
(see par. 5.4.1.1) selecting the SMART SELECTOR function. Lifting the lever will
make the support go up, lowering it will make the support go down.
2.9.2 LATERAL SUPPORT
SINGLE LATERAL GROUND-BASED SUPPORT
The side ground-based support (or arm) is delivered separately.

See the following instructions in order to fix the support:
1) position the arm at the right distance from the side of the machine. The precise
distance is indicated on the arm itself, as it varies according to the size of the
machine.
2) Fix the arm to the floor with pressure plugs by putting the plugs in the dedicated
holes on the base of the arm (see the following picture).
Before activating the arm, it is necessary to know exactly how it works. This support
was designed and built in accordance with the applicable norms and it is meant
to work only on ROCCIA S.r.l. machines. It is not an interchangeable accessory and
it will not work on other machines.
Observe the following instructions before using the machine and its support:

1) Verify the serial number plate located on the front of the support.
In addition to the number of the support, which should be used as identification

number in case of substitutions, the plate displays clearly the payload of the
machine.
By payload is meant the weight the machine can bear, not the weight it can lift.
Never overload the support, because this would damage

irreparably its structure!
2) The support is not fastened to the machine so as to allow it different positions,

depending on the desired kind of work of the machine. For the standard
positioning, lift the support arm completely and place it so that the rolls touch the
top roll of the plate roll. To produce shells with a particularly big diameter,
distance the support from the machine enough to allow it to sustain the shell.
3) To lift the support, operate the CONTROLLER lever on the control panel (see par.
5.4.1.1) selecting the SMART SELECTOR function. Lifting the lever will make the
support go up, lowering it will make the support go down.
USE OF THE LATERAL SUPPORT

Before starting with the bending, position the support at the desired distance so
that its rolls touch lightly the outer surface of the bent shell. Lift the support only
when more than one quarter of the whole shell is bent, and lightly touch its outer
surface.

Never use the fully opened support as a loading board. It was

not designed for this function and it could be damaged
irreparably. The hydraulic valves of the support are adjusted to
protect it from overloading. Never alter their calibration.
TYPES OF LATERAL SUPPORT
SINGLE SIDE SUPPORT DOUBLE SIDE SUPPORT

2.9.3 INTERCHANGEABLE TOP ROLLER
If requested, it is possible in some cases to have an interchangeable top roll. This

feature is made available for machines destined to diversified productions, e.g. for
smaller shell diameters than the standard top roll, or for the bending of different
materials requiring a different tapering from the standard one.
WARNING: in the case of small roller use. Operating, if present,

the selector of maximum machine utilization pressure reduction
as shown in Appendix D
To change the top roll it is necessary to follow these steps:
1) Open the back closure, so as to get access to the engine.
2) Open the support, without lifting the top roll, in case the roll should be lifted
hydraulically. Fasten the top roll with a band to an adequate lifting machine
able to sustain the weight of the roll.
3) Position the support pin for the top roll (see side picture)
4) Unscrew the blocking screws of the flange located on the front of the high part
of the machine: the function of the flange is to block the bearing of the top roll
(see side picture).
5) Gently extract the top roll and install the substitute roll following back all these
instructions.

2.9.4 FEEDING TABLE
THE FEEDING TABLE is used to move forward the metal plate during its processing.
Observe the following steps to fix it:
1) locate the bench at the correct distance from the side of the machine. The
distance depends on the type of work desired.
2) Fix it to the floor with pressure plugs by placing them in the dedicated holes in
the feet of the table.
2.9.5 VACUUM CONVEYOR
The vacuum conveyor is used to move the metal plate: it is a system based on
suckers and electromagnets. It lifts the metal plate from the pallet and lays it on
the roll bench leading to the plate roll.
Observe the following steps to fix it:

1) locate the conveyor at the correct distance from the side of the machine. The
distance depends on the type of conveyor and on the type of work desired.
2) Fix it to the floor with pressure plugs by placing them in the dedicated holes in
the body of the vacuum conveyor itself or in the slide rails (depending on the
model).

2.9.6 EJECTOR
The ejector of the shells is an arm with hydraulic or electric drive. It shifts in a
parallel way to the top roll (see the previous picture) thus extracting the bent plate
from the machine. The size of this accessory is determined by the capacity of the
machine and is ruled by the applicable norms. Its installation includes security
hydraulic valves and electric limit switches which prevent the ejector from being
activated in dangerous situations (e.g. when the support of the machine is still
closed).
The ejector is activated by a specific lever on the control panel. Lifting the lever
makes the ejector move outward (extraction of the piece), lowering the lever
makes the ejector return back to a stand-by position.
Never change in any way the calibration of the hydraulic valves

of the accessories, because they could be damaged
irreparably.

2.9.8 RADIUS MEASURING TOOL
This tool is used to measure the radius of curvature on the shell: the device is laid
on the bent part thanks to three points of support, and in real time its display shows
the outer radius, the outer diameter or the angle.
For further information see the specific use and maintenance manual included in
the package.
2.9.9 SHELL CALIBRATION DEVICE
The shell calibration device is a system installed only on 4-rolls machines. Its
function is to prevent the hydraulic system to pump oil in the engine of the lower
central roll. This makes it possible to lower this roll completely, consequently
working with only 3 rolls: this allows to calibrate the shell just formed, sending oil
only to the engine of the top roll.
This system (when available) is automatic. By lowering completely the central roll,
a sensor activates the oil intercepting solenoid valve, which blocks the rotation of
the lower engine, transferring all the power to the superior engine only.

2.10 ELECTROMAGNETIC ENVIRONMENT
This machine was designed to function correctly both in an industrial and a

domestic electromagnetic environment. It is fit for both, as it is in accordance with
the principles of the Harmonized Technical Standards of this product.
In particular, only components and principles tested with these standards have
been applied.
All incorporated electronic devices have been installed in accordance with the
instructions attached to them, taking into account the general criteria of
reduction of EMC phenomena.
ATTENTION!
Verify the absence within 3 m from the perimeter of the machine of
any servers, ups, general electric panels (other than those used for
the machine itself), transformer vaults, power lines (both aerial and
underground), X-ray emitters, radio – TV – telephone repeaters,
induction or microwave systems. All these, depending on the
electromagnetic field they emit, might interfere with the correct
functioning of the machine.
The welding of the shell is allowed using the ground clamp connected to the shell
itself, but absolutely not on the machine.
ATTENTION!
Welding is strictly forbidden on NC- and 2-rolls machines.

3.0 SECURITY
3.1 GENERAL INSTRUCTIONS

The operator must read carefully the information given by the present manual,
with particular attention to the security precautions mentioned in this chapter.
Moreover, the operator must necessarily observe the following precautions:
 keep the machine and the work place tidy and clean
 define some areas where to store the material in processing
 use the machine in normal psychophysical conditions only
 wear suitable clothes (no flapping garments) and personal protection
equipment (see paragraph 9.1)
 never remove or modify the identification plates on the machine
 never remove or elude the security systems of the machine
 use the machine in a covered space, protected from weather conditions
 never do any maintenance works while the machine is active
3.2 FUNCTION OF THE MACHINE

The machine was designed for the mechanical processing of metal plate in order
to give it a certain radius of curvature, creating both closed or half-open round or
elliptical tubes.
The material passes through parallel shaft rolls, following a trajectory which
determines a certain radius of curvature, depending on the reciprocal position of
the rolls. The dimension of the work space must be adequate to the size of the
metal plate to be bent.
The machine works following the modalities explained by the present manual.
For a correct functioning of the machine, it is important to always refer to the
technical features mentioned in the present manual.
It is forbidden to use the machine for any purpose other than the one explained by
the present manual. Users are therefore required to respect the limitations of use
explained in paragraph 2.7.

ATTENTION!
ONLY AUTHORIZED AND TRAINED OPERATORS MAY USE THE
MACHINE
All phases of the bending process must be followed by only one operator, who
must ALWAYS stay at the front of the machine, where the control panel is located.
During the loading of the metal plate, the operator might need help from other
people, who are allowed to stay within the range of action of the machine only
until the plate is correctly inserted in it.
While unloading the material, operators must be in front of the machine, a bit
moved on the side, so as not to be hit by the finite product.
All operations of control and measurement of the radii of curvature must be done
ONLY by the one operator at the front of the machine.
BY FRONT OF THE MACHINE IS MEANT THE SIDE WHERE THE CONTROL PANEL IS
LOCATED.
3.3 CONTRAINDICATIONS
The machine must not be used:

 for different uses other than the ones explained in paragraph 3.2
 in environments with an explosive or aggressive atmosphere, or with a high
concentration of dust and suspended matter in the air
 in environments at high fire risk
 in environments exposed to weather conditions
 with electric jumpers eluding electric safety
 if any of the protection devices is absent, damaged, insufficient
 in altered psychophysical conditions
 beyond the limitations of use mentioned by paragraph 2.7
Moreover:
It is strictly forbidden to stay or pass in the whole range of action of the machine
during its working phases
RISK OF METAL PLATE FALLING
It is also forbidden to do any operation of maintenance or registration of the
machine while the electric power is connected. All operations must be conducted
when the machine is off, in the safest possible conditions.

While extracting the shell, never grab the metal plate at its junction: ALWAYS rotate
it 180° instead.
3.4 DANGEROUS ZONES

The dangerous zones are
- entrance/exit area of the rolls
- openable support (to unhook the roll)
- electric panel
3.5 PROTECTION DEVICES

The machine is fully equipped with all the adequate pieces to protect working people
from risks caused by moving parts, explosion of pipes containing pressurized air/fluids,
risks deriving from the employ of electric current etc.
The area closest to the rolls is not protected, so as to guarantee a free and versatile
functioning. For this reason, safety standards are met thanks to alternative security
systems.
The following protection devices are installed on the machine:
1) Switch disconnector on the electric panel. If activated, it causes the immediate halt
of all actuators and the isolation from the power supply
2) Emergency stop switch on the control panel. If pressed, it causes the halt of all
actuators in safety conditions and the halt of the hydraulic pump
3) Operator-presence controls. The machines with electro-hydraulic control are

equipped with operator-presence controls. This means that a command is effective
only as long as it is kept pressed; as soon as it is released, it goes back to a rest position
4) Interlocked cable-based security system all along the perimeter of the machine
body. If activated, it causes the halt of all actuators in safety conditions and the halt
of the hydraulic pump. The position of the cable allows to activate the security system
from any of the 3 reachable sides of the machine.

3.6 STOP FUNCTIONS
The machine features the following stop functions:

a) main switch (shutdown)
b) emergency stop switch (general halt in emergency situations)
c) operator-presence controls (automatic return to a neutral position)
d) interlocked cable-based security system (general halt in emergency situations)
a) MAIN SWITCH
b) EMERGENCY STOP SWITCH
The machine is equipped with an "emergency stop switch": its activation causes
the immediate halt of all moving parts. The switch is with manual reset.
RESET AFTER AN EMERGENCY

After the reactivation, complete the following steps to restart the machine:
- remove and/or eliminate the cause for the activation of the emergency switch
- reset the switch by turning it 90° around its axis
- press the key "reset" on the control panel
Periodically verify the functioning of the emergency switch.

c) OPERATOR-PRESENCE CONTROLS (automatic return to neutral position)
The machines with electro-hydraulic control are equipped with operator-presence

controls. This means that a command is effective only as long as it is kept pressed; as
soon as it is released, it goes back to a rest position
d) INTERLOCKED CABLE-BASED SECURITY SYSTEM
A protection cable all along the perimeter of the machine delimits the closest
distance it is possible to reach. If this cable is cut or touched, the whole machine
enters an emergency state and gets blocked. The boundaries set by the cable
delimit the danger area of the machine, but it is essential to keep in mind that the
range of action of the machine is much wider, and it is necessary to signal this
area with specific panels, depending on the type of work conducted, in addition
to informing carefully the whole personnel (see the paragraph concerning the
installation).

RESET CABLE-BASED SECURITY SYSTEM

The cable surrounding the machine is connected to a limit switch with manual
reset, at the right side of the machine (from the point of view of the control panel).
This means that if the machine enters the emergency state, it will be necessary to
reset the limit switch to make the machine start again.
To do so, it is necessary to stretch the cable back to its correct tension and then
activate the button located on the limit switch.

3.7 SAFE WORKING PROCEDURES

The machine is designed to eliminate all the risks related to its use. Given the
machine’s purpose, the related risks cannot be fully eliminated. For this reason,
here below are listed the instructions concerning the operations that can be done
and those that cannot be done.
DO:
- instruct properly the operator of the machine

- verify the absence of third persons near the machine before starting it up and during its use
(otherwise interrupt immediately the production)
- handle materials with protective gloves
- use the protective helmet in case of hanging and/or directed upwards metal sheets
- always use anti-injuring shoes, helpful in case of fall of heavy pieces
- use protective glasses to protect from debris of metal, which might have torn off from the
metal plate during the bending process.
- the person who activates the machine must be the person who takes in and takes out the
metal plate
- verify the presence of a proper space in front of the machine and in the operator’s
intervention zones
- consider that the curved metal plate has the same weight of the metal plate to be curved
but in a much more concentrate space
- read carefully the plaques and the TRANSPORT signals on the machine
- trace with proper barriers and/or chains the working zone according to of the dimension of
the metal plate
THE DEFINITION OF THE SECURITY PERIMETER WILL HAVE TO BE ESTABLISHED BY THE USER
ACCORDING TO THE PROCESSED MATERIAL: IT WILL NOT BE INFERIOR TO 100 cm ON THE WHOLE
MACHINE PERIMETER.
ATTENTION!
The operator or the machine responsible can modify the
original delimitation, according to the characteristics of the
processed material, in order to create different boundaries of
the working area. Our technicians are at disposal to evaluate
the most appropriate delimitation.

DO NOT:
- use the machine without previously consulting the present manual
- remove the protection of the gears and of the other parts protected by carters
- remove the dust seal, if there is any, because it works as a protection too
- assemble or disassemble equipment with the general switch on, or when rolls are moving
- intervene on the electric system without disconnecting it from the power supply
- move the machine with inadequate lifting devices
- try to hold manually a load in precarious balance
- modify the electric system
- modify the speed of the machine’s functioning
- get distracted during the bending operations or during equipment assemblage
- touch the material while it proceeds
- work in more than one person at the same machine
- have a limited vision of the working zone, in relation to the length of the processing pieces
- use the machine beyond its maximum capacities (as explained by this manual)
- use the machine for other productions instead of curving metal sheets
- interventions on parts of the machine conducted by not specialized personnel
- install rolls or equipment not in compliance with those given by the S.r.l.
- clean parts of the machine without previously removing the tension
- use directly the hands to surmount the metal plate in case of curving beyond 360°
- stand over or under the metal plate coming in or out the machine
- activate the rotation with a hand on metal plate during the phase of incoming between the
rolls
- abandon the machine with voltage on

3.8 FURTHER RISKS
During the normal working cycle and during the maintenance, the operators are
exposed to some further risks which, given the nature of the operations, cannot be
completely eliminated:
• Risk of projection of fragments caused by the clashing of tools during the

disassembly of the mechanic parts
• Risk of being hit by some tool used for unlocking manually the mechanical parts
• Risk of being hit by processed metal plate due to the non-respect of safety
distances
FURTHER RISKS FOR ARMS

The machine for its versatility cannot be equipped with any protection in proximity
of the rolls. This could in effect enter in collision with some parts of the curving
metal plate and make the protection itself a limitation to the work of the machine.
If, as in our case, the working necessities limit the protection, the law imposes
signals to warn the operator of a close danger.
In our case, we have signaled to the operator that hands must not be used to
guide the curving metal plate. After positioning the material between the curving
rolls, as in paragraph 5, further manipulations are not necessary.
The following signal applied to the machine indicates the further risk.
FURTHER RISK FOR LEGS

During the use of the machine, there is the further risk of falling of particular objects
during manual moving: for this reason, it is absolutely obligatory to wear anti-injury
shoes with anti-pressing tip and anti-piercing sole.

3.9 MACHINE LABELS
On the machine there is the identification label concerning the characteristics with
the CE mark:
Moreover, the following warning, prohibition and obligation signals are present:
Danger crushing Danger high voltage Do not regulate or grease the

with moving parts machine during its moving
Do not remove safety devices Read the use and Use the helmet
maintenance handbook
Wear protective gloves Use protective glasses Use safety shoes

ATTENTION!
Warning safety plaques
must not be removed,
covered or damaged.
The user, after the on-ground delimitation of the safety perimeter, must place the
following signal of absolute prohibition of crossing the safety boundary line.

4.INSTALLATION
4.1 UPLIFTING
The plate roll can be uplifted by positioning the lifting bands on the rolls.
The image below shows the position of the band according to the number of rolls
present on the plate roll. The lifting bands must be sized according to the weight of
the machine.
Check that the position of the bands allows a balanced uplifting of the plate roll.
Otherwise, put the machine on the ground and reposition the bands. Do not
broaden the distance between the bands too much because they might close
under stress and cause the machine to slip.
ATTENTION!
Verify before the uplifting the absolute absence of staff
members on the ground, also considering the surface
involved in a possible tipping of the machine. Do not try to
stop the machine if it loses balance.
ATTENTION!
Do not oscillate the load for any reason: the load must be
moved vertically.

4.2 TRANSPORTATION AND MOVEMENT
4.2.1 TRANSPORTATION
1 – It is important for the machine to be transported on vehicles covered with a

tarpaulin to avoid the machine to undergo the action of the weather.
2 – Make sure that the machine, when positioned on the load area, rests well on all
the footholds. In case, level with wedges the parts that are not laying perfectly
flat.
3 – Secure the machine with wooden slats nailed to the bearing surface on the
four corners of the machine.
The machine must be loaded with the required attention. The vehicle must be
driven in respect the norms of road circulation.
The machine must be positioned on the means of transport and strongly fastened
with triangle-fixed ropes in order to avoid the load moving or falling in case of
sudden breaking, starting or bending.
4.2.2 UNLOADING AND MOVEMENT

ALWAYS and compulsorily use the bands to lift the machine, checking carefully
their payload and comparing them with the weight of the machine (APPENDIX B)
The plate roll can be uplifted by positioning the lifting bands on the rolls.
The image below shows the position of the band according to the number of rolls
present on the plate roll. The lifting bands must be sized according to the weight of
the machine. .
Check that the position of the bands allows a balanced uplifting of the plate roll.
Otherwise, put the machine on the ground and reposition the bands. Do not
broaden the distance between the bands too much because they might close
under stress and cause the machine to slide.

Test-stretch the bands before definitely uplifting the machine, and in case shift
them in order to have a perfectly balanced load.
ATTENTION!
Verify before the uplifting the absolute absence of staff
members on the ground, also considering the surface
involved in a possible tipping of the machine. Do not try to
stop the machine if it loses balance.
ATTENTION!
Do not oscillate the load for any reason: the load must be
moved vertically.
4.2.3 OUTPUT
The machine is loaded and accurately anchored to the transporting vehicle.

When loading and starting the vehicle, the transporter should be informed about
the risks and dangers of a bad transportation such as for instance sudden breaking
or unexpected and variations of direction. Moreover, a visual examination should
be carried out to guarantee the perfect state of the machine.
Therefore, if at the moment of unloading evident signs of impact are noticed, the
responsibility is to be imputed to the transporter. The most delicate points, clearly,
are the control panel and all those parts that stick out of the silhouette of the
machine. In case of a bad delivery of the load it is mandatory to signal it
immediately to the transporter and therefore proceed with the request of
damages refund, through registered mail, to the transportation company, also
sending an informative copy of the request to ROCCIA S.r.l
4.3 STOCKING AND SHUTDOWN

In case of long inactivity, stock the machine, keeping in mind the place features
and the stocking times. In particular, consider temperature range, humidity and
pollution:
- keep the machine indoors

- protect the machine from impacts and strains
- protect the machine from humidity and high temperature range (-5°C +40°C)
- avoid the machine to come in contact with corrosive substances
- open and block with a lock the electric switch on the main control board

4.4 PREPARATIONS
CASE 1 PIT INSTALLATION

WORKING HEIGHT
The considered machine, due to its dimension, might have to be collocated in a
pit. The advised working height is between mm. 800 and mm. 900. Checking the
working height of the machine (APPENDIX B) will make it easier to calculate the
ditch height. The ditch construction and the platform of the machine are
explained in the following image: it is advised to call a construction specialized
professional to analyze the ground and establish the gauge and the
characteristics of the platform. It is possible to ask to ROCCIA S.r.l for a drawing for
sizing correctly the ditch that will have to contain the machine.
ATTENTION!
ROCCIA S.r.l. declines every liability for damages to things or
people caused by an installation/positioning of the machine
differing from the instructions in the present manual.

CASE 2 GROUND INSTALLATION

The machine doesn’t need any preparation: the positioning of the machine
occurs directly on the ground or the work area.
4.5 ASSEMBLING
CASE 1 ASSEMBLED MACHINE

The machine is ready for use, no assembling is required before use.
CASE 2 MACHINE WITH NOT ASSEMBLED ROLLS

The machine needs the assembling of the rolls to function: our technicians will take
care of the assembling the parts as expected from the order.
4.6 PLACING
Pay attention during the moving of the machine: the operation must be
accomplished in absence of staff members on the ground in order to prevent
accidents. The moving of the machine must be carried out by an overhead
traveling crane or by a lift truck or by any means suitable for the purpose
(lifting/loading).
After the positioning of the machine, it is necessary to signal the safety perimeter
on the ground. This perimeter will be signaled with a yellow band of about 10 cm
of width placed at 100 cm on the whole machine perimeter, taking into account
the maximum size of possible accessories.

Proceed with the anchoring of the machine as illustrated at 4.2.2 and then position
the machine according to the following instructions:
1 The machine must be accessible from the four sides to make it possible to easily
intervene for ordinary and extraordinary maintenance.
2 On the front side of the machine it is necessary to leave a space of at least 1,5
times the nominal length of the machine (size B in the following picture). This
space is necessary for the extraction of the closed shells.
3 From the loading side of the machine (size D in the following picture) it is
necessary to consider the maximum development of the shells to be bent in
order to have a minimum transit space of at least 1 meter during the operation.
4 From the back side (size C) it is necessary to leave a space proportional to the
dimension of the metal plate to be bent, plus 1 meter for the transit.
ATTENTION!
It is advised to point out with specific signals the range of action
of the machine in order to avoid the processed materials to
accidentally hit people or things.

4.7 FIXING AND LEVELING OF THE MACHINE
It is better to fix the machine to the ground after making sure that it rests perfectly
on the surface and that it is level.
Fix the machine with pressure plugs through the dedicated holes on the base
(picture below).
It is also necessary to make sure that the base where the machine is positioned is
strong and rigid enough to guarantee a safe foothold to work by.
Check the weight of the machine indicated in APPENDIX B before installing it.
THE MACHINE IS TESTED ON A PERFECTLY HORIZONTAL BASE. AN UNEVEN, NOT LEVEL

POSITIONING WILL SURELY LEAD TO AN ABNORMAL FUNCTIONING. THE PARALLEL
ALIGNMENT OF THE ROLLS WILL SURELY BE COMPROMISED AND THE BENDING WILL
RESULT DEFECTIVE.

4.8 CONNECTION
It is recommended to have the electricity grid connection done exclusively by

specialized professionals and under the responsibility of the user.
The main switchboard is under the coverage of the motorization of the machine.
Before proceeding with the electricity grid connection verify on this board the you
machine’s type of cabling. It is always printed on the board itself. Further
verification can be done on the electric scheme attached to the documentation.
In case of changes to the machine’s voltage call the producer.

4.9 PRELIMINAR CONTROLS
Preparation operations and controls of the machine for the first start do not require
particular knowledge beyond the consulting of this manual.
Before proceeding to the start-up of the machine, it is necessary to carry out a
series of verifications and controls to prevent mistakes and accidents.
- Verify the presence of oil inside the oleo-dynamic unit
- Verify the machine has not been damaged during the transportation and
placement phases
- Verify with particular care the integrity of: main controllers, pipes, protections
- Check the correct connections of all external energy sources
- Verify the integrity of mobile parts
4.9.1 PLANETARY GEAR BOX
The machine is fully provided with oil in epicycloidal reduction gears, but still we
recommend to check the presence of oil by unscrewing the level cap before
proceeding to connection.
In case, top up with:
OIL GEARS CHART
- 20° C / + 5° C +5° C / + 40° C +40° C / + 65° C

VG ISO 100 VG ISO 150 VG ISO 320
4.9.2 HYDRAULIC POWER UNIT
Before connecting the machine to the electricity grid insert the oil in the power
unit. It is necessary to remove the carter from the covering of the engine zone to
do so.
Once identified the loading cap of the power unit, proceed with the filling.
Pour the oil until the complete filling of the glass level on the side of the power unit.
RECOMMENDED OIL
Places with temperature - 20° C + 10° C VG ISO 32
Places with temperature - 5° C + 30° C VG ISO 46
Places with temperature + 35° C + 50° C VG ISO 68

4.10 SETTING AND VERIFICATIONS
ATTENTION!
After connecting to the electricity grid, check that the electric
engine of the power unit situated in the engine compartment of
the machine spins in the correct sense of rotation, indicated by
the arrow on the engine itself.
If not indicated by the arrow, the correct sense is clockwise.
Otherwise, no movement will be possible because the water
pump will not be drawing oil.
In case the engine spins in the opposite sense, stop immediately
the machine and invert a phase of the main electric
connection.
IF THE ENGINE SPINS IN THE WRONG SENSE, THE MACHINE DOESN’T

WORK.
5.FUNCTIONING
5.1 AUTHORIZED PERSONNEL
The machine was designed for the use of one operator only.
The personnel authorized to operate on the machine must possess (or acquire by
adequate training) the requirements indicated below and, moreover, must know
the present manual and all the safety information:
- knowledge of the prevention of the main sanitary and work-related injuries
- knowledge of how to behave in case of emergency, where to find individual
protection devices and how to use them
Maintenance personnel, in addition to the above mentioned characteristics, must
also have an adequate technical and mechanical preparation.
5.2 CONTROL PANEL
The machine is provided with a control pulpit allowing total control.

The operator must be in the front area of the machine and, in any case, must not
pause or transit in the zones where the material goes in and out of the machine.
On the ground there is a boundary delimiting the safety perimeter which must not
be crossed while the machine is functioning.
This boundary must be set after the machine’s installation and it is under the user’s
responsibility. It must be properly dimensioned according to the diameter and the
dimensions of the processed material.
5.3 START-UP AND USE
5.3.1 TURN-ON
Under the engine cover of the machine there is the switchboard.

On its front side there is the door lock selector.
Turning this selector will bring power to the machine.
1 = Voltage on
0 = No voltage
On machines with electrohydraulic control, the clamp pressure regulation flier is

situated on the front shoulder of the machine. In the manual distribution version, it
is on the side of the control pulpit.

5.3.2 WORKING SPEED
The nominal speed of the machine has been studied and designed to reduce to
the minimum the level of danger. Higher working speeds could be dangerous. In
this case, it is advisable to take adequate measures to guarantee the safety of the
user.
Our specialists are at your disposal for possible practical guidance, for the
realization or for the provision of safety devices according to specific needs.
In any case, any production on the machine must be carried out with care,
common sense and attention.
ATTENTION!
One operator only must be present in the control pulpit! Other
persons on the ground must keep a distance and must not
pause inside the safety perimeter of the machine, in order to
avoid injuries.

5.4 FUNCTIONING MODES
The functioning modes of the machine are:

- MANUAL CYCLE
- AUTOMATIC CYCLE (where provided)
5.4.1 MANUAL CYCLE
ATTENTION!
Do not put your hands close to the rolls during manual
functioning!
5.4.1.1 CONTROL PANEL
This is the control panel of the machine. Controls are electrohydraulic. Check the
function of the control lever before touching them, whatever machine model you
have. By the way, how you see in the picture, there are icons to immediately
explain the functions, in addition to the relative writings.

Numbered scheme
Number Description
1 Command RIGHT / LEFT rotation
2 OPEN / CLOSE release
3 Command UP / DOWN central roll
4 Command UP / DOWN left roll
5 Command UP / DOWN right roll
6 SMART SELECTOR handle
7 CONTROLLER assigned by SMART SELECTOR
8 Rotation speed selector
9 PUMP START
10 PUMP STOP
11 EMERGENCY RESET button
12 Manual / Automatic key selector
13 Shaft visualizer
14 EMERGENGY STOP mushroom-shaped button
15 Left roll inclination lever
16 Central roll inclination lever
17 Right roll inclination lever

5.4.1.2 MOVEMENT
2 ROLLS
The moving parts do not require maintenance because they are not subject to
wear. The central roll “b” rests thanks to a support on two “g” eccentric rolls
connected by a torsion bar.
The “b” rubber-coated roll is motorized.

3 ROLLS
All the movement are of planetary-type and they do not require maintenance
because they are not subject to wear. The two “c” and “d” bending rolls move
thanks to forks and therefore do not slide on rails of any kind. The rolls are moved
by the “f” cylinders.

4 ROLLS
All the movements are of planetary-type and they do not require any
maintenance because they are not subject to wear. The two “c” and “d” bending
rolls move thanks to forks and therefore do not slide on rails of any kind. The rolls
are moved by the “f” cylinders. Thanks to two supports, the “b” central roll rests on
two “g” eccentric rolls also connected to the torsion bar. The “a” and “b” rolls are
motorized in order to guarantee a good dragging of the metal plate when it is
pinched between them.

5.4.1.3 MOTORIZATION
"HR2W" 2 rolls machine

The motorization consists of one hydraulic engine connected to the planetary
gear, which is directly assembled on the inferior rubber-covered roll.

The motorization of the 3 rolls consists of 3 hydraulic motors connected to the
planetary gears directly assembled on the rolls.
The distribution of oil is independent for each of the 3 motors. This allows the rolls to
adapt, when needed, to the different rotation speeds they face during the phases
of the bending.
Because of the thickness of the metal plate, the inner part of the shell is always
shorter than the outer, although both have to be covered in the same timespan. It
is clear, therefore, that the thicker the metal plate is, the more the speed
necessary to cover the inner/outer part will be different. This type of direct
assembling on rolls offers the advantage of friction; in addition to that it allows to
avoid all kind of secondary transmission, and therefore all need for maintenance
and lubrication that are typical for gear-transmission machine
The engine of the two central rolls is made of two planetary gears, directly fitted
together on rolls. Two hydraulic engines with independent control are assembled
on these rolls.
ATTENTION!
CONTROL THE FASTENING SCREWS OF ENGINES AND GEARS
AFTER 8 – 10 WORKING HOURS OR ANYWAY WITHIN THE FIRST 3
WEEKS OF WORK. AFTERWARDS, CONTROL PERIODICALLY
ACCORDING TO HOW OFTEN THE MACHINE IS USED.

5.4.1.4 GEOMETRY AND REGULATION OF THE MACHINE
2 ROLLS
The “a” top roll is fixed and can only rotate. The lower roll is built on two supports
running on two rails and they rest on a “13” eccentric roll, which is integral part of a
“12” eccentric bar. The “9” oleo dynamic cylinder/ two cylinders, by pushing,
create a circular movement which, moving the eccentric roll, makes the roll
himself go up/down.

3 ROLLS
The”a” top roll is unmovable and can only rotate. The two “c” and “d” side rolls
are built on two “4” piston rods, which, under the thrust of the hydraulic “7”
cylinders and being pinned at their ends, move creating a semi-circular
movement which approaches the rolls themselves to the top roll.

4 ROLLS
The “a” top roll is unmovable and can rotate only. The two “c” and “d” side rolls
movement, which approaches the rolls themselves to the top roll. The lower roll is
built on two supports running on two rails and they rest on a “13” eccentric roll,
which is integral part of a “12” eccentric bar. The two “9” oleo dynamic cylinders,
pushing, create a circular movement which, moving the eccentric roll, makes the
roll himself go up/down.

NUDA
c d
The “a” top roll is unmovable and can rotate only. The two “c” and “d” side rolls
movement, which approaches the rolls themselves to the top roll. In case there is
a need to reset the two side rolls parallel position use the screw pointed by the red
arrow.

5.4.1.5 REGULATION OF THE PARALLEL POSITION OF ROLLS

All the following operations refer to the drawings of the previous page.
ONLY FOR 2 AND 4 ROLLS

Central Roller. At the two ends of the eccentric bar there are two eccentrics, on
which the support inferior roll rests. To regulate the screw of this support, release the
fixing screw. Now you can regulate the height intervening on the screws.
Side rolls. If the side rolls are not perfectly parallel to the top roll it is possible to
intervene for their regulation thanks to the electronic parallelism controller. Read
the specific manual.
5.4.1.6 USE OF THE MACHINE

Preliminary information
Correct maintenance and regular cleaning of the machine guarantee the highest
efficiency.
Cleaning of the metal plate

The state of the material to be processed is of great importance. Therefore, it is
necessary to make sure that the metal plate is prepared in the following way
before going in the machine:
- Eliminate the remains caused by oxy-fuel cutting. All the sides and the
corners of the metal plate must be cleaned and grinded with a grinder.
- Eliminate, if present, any type of remain of welding with a grinding machine
on the metal sheets’ surfaces. The remains could seriously damage the
surface of the rolls, even if it is treated.
- Eliminate carefully all the calamine on the metal sheets’ surfaces.
- Proceed with the cleaning of all the remains still present on the metal plate
after the previous treatments.
ATTENTION!
THE STATE OF THE METAL PLATE STRONGLY AFFECTS THE QUALITY
OF THE FINAL PRODUCT.
In some cases, it could be necessary to sandblast the metal plate.

Quality of the metal plate:

As known, when working with average quality metal plate, it is possible to notice
some differences within the same material.
The following factors can influence negatively the repeatability of the final product
even within the same machine parameters.
1) Quality of the metal plate
2) Yield point limit
3) Elasticity coefficient
4) Thickness homogeneity
5) Leveling sense
These are the most important factors that can limit the bending tolerance, one or
more of them at the same time.
For instance, the machine parameters being equal, a metal plate with a higher
elastic return will originate a shell of larger diameter. Moreover, if a metal plate is
bent in the same direction as it was flattened (that is, with broken fibers) it will
behave differently from a plate that is bent in a perpendicular direction to the one
it was flattened.
This lack of homogeneity is often to be noticed within the same metal plate.
Because of this, it is important to ensure the highest quality of the material at the
moment of the purchase. These problems are to be better observed on the
Numeric Control machine where the rolls’ placement is guaranteed by
sophisticated electronic devices. In effect, although the rolls always stop in the
same position, they sometimes produce shells with different diameters. At the same
time, it is possible notice a variation of the plate roll diameter even if the position of
the roll is obtained after one or more passes of the metal plate. This happens
because at the first pass the metal plate is broken in its fibers, and in the following
passes its elasticity increases.
THEREFORE, THE PRODUCING COMPANY DECLINES EVERY RESPONSIBILITY ON THE

NON-REPEATABILITY OF THE PIECES IN SEQUENCE, BECAUSE THIS FACT ALWAYS
DEPENDS ON THE BAD TOLERATION OR ON THE LACK OF HOMOGENEITY OF THE
METAL PLATE ITSELF.
Other bending defects can be encountered during the bending of big diameters:
both at the beginning of the bending operation (when the metal plate is all
curved on one side only of the machine) and during the bending operation, the
metal plate tends to change its normal radius of curvature. Therefore, it is
advisable to provide the machine with devices such as the central bridge or side
support to limit these inconveniences.

5.4.1.7 PROCESSING PHASES

The following pictures illustrate the normal work cycle of a plate roll. The operator's
experience has a determining influence on the quality of the final product, as well
as on the bending time.
Before inserting the metal plate into the machine, it is necessary to check that the
middle lower roll is at the bottom and, if necessary, to lower it.
The following picture illustrates all the operations in a normal plate roll cycle. In this
case the metal plate is inserted from the left side of the machine, however it is also
possible to insert it from the right side of the machine. Clearly in such case all the
operations will have to be executed specularly.
2-ROLLS machines
Lift the middle roll until the desired pressure is obtained. Push the metal plate
between the rolls so that it is
pinched between the lower rubber
roll and the higher roll. Activate the
rotating cycle on the desired
length of the metal plate. Activate
the descent-lever of the lower
rubber roll; if necessary, release to
remove the material, and close
once it is removed.
The picture on the right

illustrates the final result.

The top roll diameter is what determines the rolling diameter.

To change the rolling diameter of a small value you can change the pinchin
pressure of the rubber roll. A saddle change of 15-20 mm can be done by
adjusting the pressure of abiut 20 bars.
To change the rolling diameter of a larger values you have to either change the
top roll with a larger one or just install on the top roll a pipe with the desired rolling
diameter but about a 10-15% smaller. However the diameter of the pipe that we
cann former roll depends on the type of material and its spring back.
See the picture below to see how to install the former roll.
The installation is as easy as slide the pipe on the top roll. The larger diameter of the
top roll will change the footprint in the rubber and consequently the rolling
diameter. Roccia offers upon request special supports to hold up the former rolls
when they are large.

3-ROLLS machines
Lift the right roll until it is positioned
about halfway of its run. This
operation creates a contrast
which allows the squaring of the
metal plate. Insert the metal
plate: position it on the left roll,
stick it close to the center of the
right roll, then push the right roll
upwards to press the metal plate.
Bring the metal plate as close as

possible to the pinching point, so
that the pinched part starts from
the beginning. In order to do so,
activate the rotating control.
Lift the left roll until the desired radius of curvature is obtained, then start moving
forward the metal plate until it reaches ¼ of the total length to be bent.
It is now necessary to create the start of the curvature also on the other side of the
metal plate. In order to do so, repeat the same operations as before, of course
inverting the movements of the left roll with those of the right roll.
Once both of the starts of the curvature

are complete, it is possible to close the
shell by moving it backwards and
forwards and lifting alternatively the
side rolls , in order to close the shell
constantly at each pass.
The picture on the right illustrates the
final result.

3-ROLLS variable axis machines

In these machines, the arrangement of the rolls is the typical pyramid arrangement, with
the upper
roll fixed and the two side rolls transferred on swing arms toward it.
The rotation is by means of all three rolls, with three independent drive unit. The sequence
of the
operations highlights the rolling procedures.
1. The feed is horizontal, therefore a roller table can be used reducing the hazards caused
by the
handling of inclined heavy sheet metal.
2. The alignment with the side roll (Left), that

acts as striker, facilitates the preliminary
positioning of
the sheet metal. To prepare the material to
be pre-bent move the Left roll to the right and
move
the top roll down to touch the plate
3. Now press the plate by means of the top roll to the desired radius and feed the material
toward the left as shown in the below
picture ( we suggest to start bending it a
little at first and
then check what diameter you are rolling
the plate to)

4. Just do the same thing in the other side of the plate in order to get both edges bent.
5. Feed the material to be placed about in the center of the rolls and start to bend it by
lowering the
top roll A and feeding it back and forth. Bend a certain amount and then pass the material
from left
to right and vice versa
6. The above mentioned operation will let you close the shell as shown on
the picture below
By playing with the three movement,

side rolls left and right and top roll up
and down you can find
the better geometry to allow the
machine to close the shell with the
minimum flat on edges.

4-ROLLS machines
Lift the right roll until it is positioned

about halfway of the middle rolls.
This operations creates a contrast
with the roll itself, which allows the
squaring of the metal plate. Insert
the metal plate between the
middle rolls and push it to stick it on
the right roll. It is now possible to lift
completely the lower roll to pinch
the metal plate between the two
middle rolls. On this machine it is
also possible to adjust the pinching
strength. The appropriate pinch
pressure will be illustrated later in this
paragraph.
Lower now the right roll and drag
the metal plate towards the left,
bringing its edge as close as
possible to the axis of the middle
rolls. Lift now the left roll until the
desired radius of curvature is
obtained, then drag the metal
plate towards the right (the
movement of the rolls is shown on
the digital display
and the resulting radius of curvature

depends not only on the thickness
of the metal plate, but also on the
kind of material). Stop the metal
plate when it can be positioned on
the right roll.
Lift the right roll to position the metal
plate, then lower the left roll all the
way down. It is now possible to
continue dragging the metal plate
until the bending is complete. The
picture on the right illustrates the
final result.
In some cases, defects occur during the bending process: such defects are, more
specifically, the "Barrel" defect (pic. 1) and the "Spool" defect (pic. 2).

Picture 1 Picture 2
The rolls of the plate rolls are designed to overcome these defects. Their surface is
not, in fact, perfectly cylindrical, instead it is bi-conical.
The conicity of the rolls is designed to ensure performance for a greater number of
thicknesses. Clearly, however, the final result of the bending process on material
with extreme measures (maximum or minimum bending thickness) may present
these kind of defects.
DEFECTS AND ADVICE ON HOW TO RESOLVE THEM
"BARREL" DEFECT
The “barrel” defect is a deformation of the shell, closed at both ends and open in
the middle. This defect may be due to the flexion of the rolls strained by the
bending.
Cause 1
The thickness of the metal plate is superior to the performance capacities of the
machine.
Remedy
The only remedy is to roll the material on a machine with higher performance
capacities.

Cause 2 (only applying with 4-rolls plate roll)

The metal plate is pinched between the two middle rolls with excessive pressure.
Remedy
Slightly reduce the pinching pre-load (rising pressure of the lower roll). This
operation can also be executed exclusively on the last passes. Clearly, by
reducing the pre-load, the length of the first straight section will be increased.
"SPOOL" DEFECT
The “spool” defect is the deformation of the shell, closed in the middle and open
at both ends. This defect may be due to the bi-conicity of the rolls.
Cause 1
The metal plate is too thin for the machine.
Remedy
The only remedy is to roll the material on a machine with lower performance.
Cause 2 (only applying with 4-rolls plate roll)

The pinching pressure on the metal plate is too low.
Remedy
Slightly increase the pre-load of the rolls.
"TRUNCATED CONE" DEFECT

Because of this defect the metal plate closes in a more accentuated manner on
one side of the shell rather than on the other.
This defect may be due to two different situations.
Cause 1
The rolls are not perfectly parallel to each other.
Remedy
Check the parallelism of the rolls and, if necessary, proceed to correct it.
Cause 2
The metal plate is shorter and it is not positioned in the middle in relation to the
rolls’ width.
Remedy
Un-pinch the metal plate and position it in the middle. If the problem persists,
slightly tilt the side rolls so as to compensate the bending defect.

“OVALISATION” DEFECT
The “ovalisation” defect is the crushing of one side of the shell. Its diameter is
irregular and one of the two axes is bigger.
Cause
This defect may be due to the metal plate dimensions.
Remedy
Calibrate the shell by lowering the lower roll on its way down for 4-rolls machines
with an automatic system. This operation must be executed exclusively with the
lower roll completely at the bottom, otherwise the welding work, or any other work,
may seriously damage the machine.
"ROLLING" DEFECT
Cause
This defect may be due to an excessive pre-load of the roll. The metal plate
coming out of the machine gets laminated, therefore irretrievably damaged.
Remedy
Adjust the pressure-regulating valve of the pinching roll and reduce its pre-load.

"OFFSET" DEFECT
Cause
This defect may be due to a misalignment of the metal plate, to an incorrect
parallelism of the rolls or to a metal plate with irregular thickness.
Remedy
Check the alignment and the parallelism. If the defect is due to the material, there
are no solutions.

5.4.1.8 CONE BENDING

With the hydraulic system of cone bending it is possible to operate bending on
truncated cones. Such an operation is one of the most complicated the machine
allows to perform and it requires a particularly skilled operator.
Since this operation is particularly complicated to execute, THE PERFORMANCE OF
THE machine SHOULD BE CONSIDERED AS REDUCED BY ½.
This means that the machine is able to bend cones with length and thickness
exactly halved compared to the nominal performance of the machine.
Information on the bending of cones

In order to obtain a truncated cone, it is necessary to prepare the metal plate by
shaping it on the basis of the smaller base, the larger one and the height of the
cone.
Once the measures of the finished cone are defined, it is possible to proceed to
cut the metal plate on the basis of the following calculations and respective
pictures:
L= (D∗ I )(D− d )
R− r 2
I=√h2 +
S
∂= ∗ 180 °
π∗ L
S=D∗ π
π= 3,14

MACHINE SET-UP
Before inserting the metal plate into the machine, it is necessary to prepare the
machine as follows:
1) For 4-rolls machines, lift the rear part of the middle lower roll, so that the metal
plate is pinched only on the side opposite to the cone support.
2) Tilt the side roll as much as necessary in order to work with the cone correctly.
Most cones can be bent with the maximum tilt angle, which is 1,5°.
Such limit is due to the tilt limit of roll bearings, and it is the same in all machines.

INSERTION OF THE METAL PLATE

The part coincident with the smaller base of the cone must ALWAYS point towards
the operator pulpit and must rest firmly on the special cone support.
Working phases
1) Insert the first part of the metal plate to be curved in between the two middle
rolls and as close as possible to the axis of the rolls, taking special care of the
alignment.
Follow the steps of normal bending for all following operations.
Since working with conical shapes can be complicated and particularly strain the
machine, it is necessary to take proper care of the cleaning and preparation of
the metal plate prior to starting work.
Normally, during the bending of cones, the tipper support can slightly open, as it is
strained by the push of the cone. If it opens too widely, check again the size of the
cone and make sure the machine can perform the work.
If it can, the defect may be due to a too high yield strength of the metal plate, in
which case the material should be replaced.
In some cases it is possible to attach retainers for the tipper support, as you can see
in the following picture. It should be borne in mind, however, that this procedure
adds too much rigidity to the structure and that, by overloading it, other parts of
the machine may be damaged.


5.4.2 AUTOMATIC CYCLE
If the machine disposes of a controller for operating an automatic work cycle,

operate as follows:
- rotate the door-lock switch to position 1
- push the button START PUMP
- select the automatic program to operate
- rotate the selector switch to AUTOMATIC
- follow instructions on the display of the controller
- insert the metal plate into the machine when the program suspends
- follow instructions on the display of the controller
- at the end of the work, remove material from the machine
5.5 COMPLETION OF WORK
At the end of the work, execute the following operations:

- remove the material from the machine
- position the shafts in the mechanical limit switch
- close the opening support
- stop the hydraulic pump
- rotate the door-lock switch to position 0
Refer to the specific controller manual affixed on the machine for further detail
regarding the programming.

6.0 MAINTENANCE
6.1 MAINTENANCE OPERATIONS
This paragraph contains recommendations regarding the periodic maintenance.

Periodic maintenance is an essential precondition to ensure the safety of the
personnel. With periodic maintenance the risk of expensive repair operations and
loss of production is minimized. The intervals indicated for all operations are
necessarily approximate, as they depend on how the machine is used, etc.
These recommendations can be adapted to the specific use of the machine and
through the experience of your maintenance personnel.
It is recommended that the daily maintenance operations and the continuous
visual inspection of the machine are performed by the operator of the machine.
All other maintenance operations must be performed by specialized personnel.
We remain at your disposal for further information on how to perform maintenance
operations and for the training of your staff. Our technical support is organized to
resolve any production problem you might encounter.
Therefore do not hesitate to contact us if you need to solve a problem.
6.2 MAINTENANCE STATUS
Maintenance procedures must be performed with the machine in the conditions

described below.
6.3 MACHINE INSULATION
Before performing any kind of maintenance or repair, it is mandatory to isolate the

machine from all of its power sources, operating as follows:
- disconnect the electric power supply.

6.4 SPECIAL PRECAUTIONS
While performing maintenance or repair, it is recommended to operate as follows:

- before starting work, affix a sign "MACHINE UNDER MAINTENANCE" in a visible
position
- do not use solvents or flammable material
- take care not to dump lubricating liquids into the environment
- do not climb on the parts of the machine because they are not designed to
support the weight of people
- at the end of the work, reset and properly fix all protections and fixed guards
previously removed or opened, as well as all safety devices previously removed.
MACHINE UNDER MAINTENANCE

UNAUTHORIZED PERSONNEL
NOT ALLOWED
6.5 CLEANING
It is recommended to frequently clean the machine (depending on the kind and

frequency of its use). Daily cleaning is recommended.
Disconnect all of the power sources of the machine.
Before cleaning the machine, the operator must wear all the
proper safety devices indicated in the dedicated paragraph.
Make sure of the absence of third parties nearby while cleaning
the machine.
An air-jet blowing of the machine can be performed after

verifying the absence of third parties nearby and wearing safety
glasses with side shields. Air pressure must not exceed 3 bar.

6.6 ORDINARY MAINTENANCE
All procedures described below must be performed with the methods and
deadlines indicated: in case of non-compliance with the following directions, the
producer will be exonerated of any responsibility regarding the lifespan of the
product.
Such procedures are simple, however they must be performed by properly trained
personnel, therefore the personnel:
- must be provided with proper information about the risks inherent the machine
(such as electric and mechanical risks)
- must acquire specialized knowledge regarding the kind of procedure he must
perform
- must be fully equipped with the necessary obligatory safety equipment in
accordance with the applicable law dispositions.
If during an intervention it is indispensable that the control panel

stays active, these procedures must be performed by electricly
trained operators.
Ordinary maintenance includes inspections, checks and interventions with the aim
of preventing breakdowns due to faults or potentially dangerous situations.

SECURITY CHECKS BY THE MACHINE OPERATOR
No. Operation Frequency Procedure

All fixed guards must be placed
correctly in their place and in
good state.
Their warning signs must not be
removed.
Daily check integrity of fixed
Furthermore check:
Fixed guards guards (do not use the
1 - wear of junctions and
integrity machine if the fixed guards
fastening points
are damaged or removed).
- loss or damage of parts of the
fixed guards
- maintaining of original safety
distances and opening
dimensions.
Daily check integrity of the All switches/levers must be
Switches/Levers switches/levers (do not use intact. Their warning signs must
2
integrity the machine if the switches be readable.
are damaged).
Daily testing integrity rollers The rollers must not show any
3 Rollers integrity (in case they are damaged abnormality in the totality of the
do not use the machine) surface.
Daily integrity check of the Safety devices must be
following devices: completely intact and their
- stop emergency button warning signs must be readable.
Safety devices - security rope
4
integrity - door-lock switch
- control panel
(do not use the machine if
they are damaged)
Daily check of the The attendant machine has the task
lubrication of release levers: of checking the lubrication of the
Lubrication of if sliding parts are not sliding parts do not perform
5 lubricated, please contact
release levers lubrication as such activity is
maintenance service. reserved for the maintenance
service.
Daily check for absence of The operator must only check
oil leakage from the for the absence of oil leakage:
hydraulic power unit as well he must not perform any
Control oil for as from supply lines of intervention, since such activity
6
leakage actuators (in the event of a is reserved to the maintenance
leak, do not use the personnel.
machine and contact
maintenance service).
All of the above mentioned checks do not need to be registered.

OBLIGATORY
If during inspection the operator finds an anomaly, he must refer
to his superior so that maintenance personnel can check the
machine.
SECURITY CHECKS BY THE MAINTENANCE SERVICE
No. Operation Frequency Procedure
Check weekly lubrication of The attendant machine has the task

the bushings and bearings: in of checking the lubrication of the
Lubricating bearings the case where the parts sliding parts do not perform
7 subject to sliding are free of lubrication as such activity is
and bushings
lubricant, contact the reserved for the maintenance
maintenance service service.
Monthly check of the Activate the device to check its
efficiency of safety devices efficacy. Reset must be
8 Security devices (door-lock switch, stop performed by following the
emergency button, security procedures explained in
rope). paragraph 3.6.
Monthly check of the oil Top-up if necessary (annual
Hydraulic power
9 level in the tank of the replacement).
unit
hydraulic power unit.
Monthly check oil level in Top-up if necessary (annual
10 Gearbox
the gearbox. replacement).
Monthly check saturation Replace if necessary (annual
11 Oil filter
level. replacement).
Release, rolls Weekly grease of the lateral Grease the rubbing surfaces
12
housing rubbing surfaces. with a brush.
Annually check sliding Remove the reduction bell gear
bushes conditions. and check the conditions of the
13 Roll Housing
sliding bushes. Replace if
necessary.
Gearbox unit fixing Monthly check of the fixing Check the tightening of all
14 screws
screws screws securing the gearboxes

For any other maintenance intervention, refer to the data sheets of the
components annexed to the present manual.
ATTENTION!
Protections and safety devices of the machine must not be
removed if not for the purposes of work.
If they need to be removed, appropriate measures must be taken
immediately in order to highlight and minimize any resulting
danger.
Previously removed protections or safety devices must be
replaced immediately after the conclusion of the work which
required their temporary removal.
ATTENTION!
It is forbidden to clean, oil or grease by hand the moving parts of
the machine
ATTENTION!
It is forbidden to carry out repair or adjustment operations of any
kind on moving parts.
Dedicated plates recalling these warnings are affixed on the machine.
6.7 EXTRAORDINARY MAINTENANCE
Extraordinary maintenance must be performed by our support service; when

necessary, contact the support service at the number indicated in paragraph 1.1.

7.0 DIAGNOSTICS
7.1 ALARMS AND FAULTS
The plate roll is equipped with the following fault and alarm indicators:
FAULT OR ALARM REPORTING MODES SOLUTION

Message on the display
Exhaust filter Clean / change filter
OIL FILTER EX
Reset thermal
Thermal cut-out electromechanical
OVERLOAD
protection
Remove condition which
Emergency generated the
EMERGENCY
emergency
Message on the display Refill oil and reset
Oil level below minimum
OIL LEVEL LOW minimum level
7.2 TROUBLESHOOTING
VERIFICATIONS AND/OR
INCONVENIENT CAUSE
REMEDIES
Check that the electric switch
The machine does not start- door-lock is on 1 and that
Lack of power supply
up
voltage is supplied 1
Check that:
- the button RESET EMERGENCY
has been pushed or the arrest
button has been reset
The hydraulic power unit
Presence of alarms - the button PUMP START on the
does not start-up
operator pulpit has been
pushed
- there are no alarm indications
on the display
- Check the oil level in the tank of
Pressure in hydraulic circuit is the hydraulic power unit
Cylinders do not rotate not suitable - Check on the pressure gauge
on the hydraulic power unit that
the pressure is right

.... following
VERIFICATIONS AND/OR
INCONVENIENT CAUSE
REMEDIES
- Check the oil level in the tank of
the hydraulic power unit
Pressure in hydraulic circuit is
Shafts do not move - Check on the pressure gauge
not suitable
on the hydraulic power unit that
pressure is suitable
1 Check the integrity of the fuses in the control panel and the main outlet.
If the problem persists, please contact the producer.
7.3 REQUEST OF SUPPORT
Support request must be sent by fax or e-mail:
FAX: 0039-0172-474324

8.0 REPLACEMENT PARTS
8.1 SPARE PART LIST
In the event of a machine breakdown or damage, contact the producer in order

to define the necessary interventions for its repair. Depending on the damage, it
will be taken under consideration whether the guarantee covers the repair, as
indicated in the conditions in paragraph 1.3.
The producer must be informed of the list of damaged parts, and will need in
detail the following information:
MODEL
SERIAL NUMBER
The CE marking affixed to the machine indicates all this information.

The producer will establish a list for the effectuation of the order.
8.2 ORDERING REPLACEMENT PARTS
Intervention request must be sent by fax or e-mail:
FAX: 0039-0172-474324

9.0 INDIVIDUAL PROTECTION DEVICES
9.1 PPE IDENTIFICATION
SAFETY REQUIREMENTS
The use of the machine requires operative and maintenance personnel to wear
specific personal protective equipment. Note that the use of PPE listed below is
mandatory. Such obligation is reiterated by the applicable laws on health and
safety at work, therefore the non-use of PPE is punishable by law.
9.1.1 PPE FOR THE ORDINARY USE OF THE MACHINE
PROTECTION
Wear the following personal protective equipment (P.P.E.):
Feet: non-slip footwear with non-crushing steel toecaps and non-drilling soles
Hands: fabric gloves to prevent abrasion during the loading of metal sheets
Body: protective clothing against soiling
Ears: earplugs or other hearing protection devices (for machine models HR3W and
HR4W, from size F on)
HYGIENE
Take the following hygiene measures:
Do not eat or smoke with dirty hands.
Wash hands thoroughly after using the machine.
FIRST AID
In the event of an accident while using the machine, immediately contact the First
Aid Responsible and, if necessary, National Health Service for necessary care.

9.1.2 PPE FOR MAINTENANCE OPERATIONS
The same personal protective equipment must be worn during maintenance

operations.
Note : the use of further protective equipment, such as protection of airways, eyes,
ears, etc., must be indicated by the responsible person in function of the
environmental residual risks arising (hence not attributable to the machine).

10.0 PERSONNEL TRAINING

10.1 TRAINING OF THE OPERATIVE PERSONNEL
The use of this machine requires the instruction of the operative personnel
(information and training). Training is required in order to acquire practical
knowledge of adjustments and maneuvers regarding the use of the machine as
well as its residual risks.
Once the operator achieves a sufficient confidence and knowledge level of all
control devices, he will be able to handle efficiently and safely the automatic
procedures which allow a rapid and continuous working.
Operative training is performed by ROCCIA S.r.l. personnel and covers the
following points:
a) Adjustments and control for machine start-up
b) Use of control devices
c) Operation criteria
d) Knowledge of security devices
e) Use of the user manual
f) Regular maintenance
ATTENTION!
ROCCIA S.r.l. declines all liability for any damage to objects and
persons if the above-mentioned precautions are not complied
with.

11.0 DEMOLITION
11.1 DISPOSAL OF PROCESSING WASTE
Processing waste must be disposed in accordance to the existing legislation

concerning processing waste. All waste must be disposed as far as possible as
soon as it is produced, in order to avoid potential hazards. Temporary storage on
the production site must pursue environmental protection requirements.
11.2 DEMOLITION OF THE MACHINE
Hydraulic oils and lubricants used on the machine must be considered as special
waste, therefore their disposal must comply with the laws of the country in which
the machine is installed.
During the demolition, plastic parts must be separated from electric components,
which are destined to selective collection in accordance to the existing legislation.
As far as the machine metal mass is concerned, iron parts must be separated from
other metal or alloys parts, in order to recycle them correctly through fusion.
Demolition does not present any particular risk, as long as it is performed by
sufficiently qualified technicians with appropriate equipment.

APPENDIX A
“CE” Declaration of Conformity
(pursuant to the Machine Directive, annex II letter A)
The producer Roccia s.r.l..

Address of the factory: Via dell’artigianato, 30 - 12040 S.Albano Stura CN Italy
Tel. +39 0172- 474388
Telefax +39 0172- 474324
DECLARES THAT THE OIL PLATE ROLL WITH THE FOLLOWING FEATURES:
Model NUDA
Type 2520
Serial number 20111
Built in 2020
IS IN CONFORMITY WITH THE LEGISLATIVE INSTRUCTIONS IN FORCE TRANSPOSING THE MACHINE

DIRECTIVE 2006/42/CE AND ITS SUBSEQUENT AMENDMENTS
Technical dossier in the European Community made up by Roccia Srl Via

dell’Artigianato, 30 12040 Sant’Albano Stura CN Italy
The producer forbids the use of the machine subject of this declaration for any purpose
differing from the above mentioned.
The producer declares that the machine is in accordance with following European
directives (when applying): 2014/35/CE, 2014/30/CE.
Delegate responsible:
Position: CEO Gabriele Roccia
S.Albano, 18/11/2020

APPENDIX B
Technical Data of the machine
Length mm. 5200
Width mm. 1450
Height mm. 1600
Work length mm. 2600
Top roll diameter mm. 320
Top roll weight kg. 1900
Lower roll diameter mm. ---
Lateral rolls diameter mm. 300
Electrical power kW. 11
Total weight kg. 8500
Bending thickness mm. 20
Prebending Thickness mm. 16
Rotation hydraulic pressure bar 150
Services hydraulic pressure bar 180

APPENDIX C
BENDING CAPACITY 20 20,0

PRE-BENDING CAPACITY 16 16
TOP ROLL DIAMETER 320 320

MACHINE LENGHT 2500 2.500
WORKING
MATERIAL YIELD N/mm2 MODE
Flat Times material thickness
Flat on each
Width Diameter Rolling Thickness Pre-Bending Thickness ends
2500 352 12,0 12,0 60,0

2500 416 13,0 13,0 65,0
2500 480 15,0 15,0 75,0
2500 640 17,0 17,0 85,0
2500 960 18,0 18,0 90,0
2500 1600 20,0 20,0 100,0
2500 3200 21,0 21,0 105,0
2083 352 13,1 13,1 65,7

2083 416 14,2 14,2 71,2
2083 480 16,4 16,4 82,2
2083 640 18,6 18,6 93,1
2083 960 19,7 19,7 98,6
2083 1600 21,9 21,9 109,5
2083 3200 23,0 23,0 115,0
1696 352 14,6 14,6 72,9

1696 416 20,7 15,8 78,9
1696 480 18,7 18,2 91,1
1696 640 20,6 20,6 103,2
1696 960 21,9 21,9 109,3
1696 1600 24,3 24,3 121,4
1696 3200 25,5 25,5 127,5

BENDING CAPACITY 20 17,4

PRE-BENDING CAPACITY 16 13,92
TOP ROLL DIAMETER 320 320

MACHINE LENGHT 2500 2.500
WORKING
MATERIAL YIELD N/mm2 MODE
Flat Times material thickness
Flat on each
Width Diameter Rolling Thickness Pre-Bending Thickness ends
2500 352 10,4 10,4 52,2

2500 416 11,3 11,3 56,6
2500 480 13,1 13,1 65,3
2500 640 14,8 14,8 74,0
2500 960 15,7 15,7 78,3
2500 1600 17,4 17,4 87,0
2500 3200 18,3 18,3 91,4
2083 352 11,4 11,4 57,2

2083 416 12,4 12,4 61,9
2083 480 14,3 14,3 71,5
2083 640 16,2 16,2 81,0
2083 960 17,2 17,2 85,8
2083 1600 19,1 19,1 95,3
2083 3200 20,0 20,0 100,1
1696 352 12,7 12,7 63,4

1696 416 18,6 13,7 68,7
1696 480 16,3 15,8 79,2
1696 640 18,0 18,0 89,8
1696 960 19,0 19,0 95,1
1696 1600 21,1 21,1 105,6
1696 3200 22,2 22,2 110,9

APPENDIX D
Rotating the selector a pressure reduction valve is activated to reduce the so
as not to damage the reduced roller and the machine maximum folding
pressure. Skip this procedure puts at risk safety of the operator

Master Plate Roll 2nd Ediz 6rev ENG

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INSTRUCTION MANUAL Date:.10.

ROCCIA S.r.l. Via dell'artigianato, 30 - 12040 S. Albano Stura (CN) Italy -

Date: 10.2020 Edition: 2 Revision: 6

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3.8 FURTHER RISKS ............................................................................................................... 28

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7.2 TROUBLESHOOTING ...................................................................................................... 76

10.0 PERSONNEL TRAINING ....................................................................................................... 81

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 4 of 87

1.0 GENERAL INFORMATION

1.1 IDENTIFICATION DATA OF THE PRODUCER

SEAT Via dell’artigianato, 30

12040 S.ALBANO STURA

TEL. 0039 0172.474388 FAX. 0039 0172.474324

CEO ROCCIA Gabriele

Born in Savigliano (CN), Italy on the 18.08.1989

T.C. RCC GRL 89M18 I470B

VAT CODE 03384510040

TAX CODE 03384510040

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 5 of 87

The machine was realized in accordance with the applicable Community

mentioned on the tax documentation delivered with the machine. It includes:

- 12 months on the mechanical part

Fax: 0039 0172 474324

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 6 of 87

1.4 STRUCTURE OF THE MANUAL

Users are kindly asked to read very carefully the following

1.5 ARRANGEMENTS TO TO BE PROVIDED BY THE USER

The user must provide for the following arrangements:

Realization of the demarcation lines to delimit the dangerous zone potentially

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 7 of 87

1.6 AIM AND CONTENT

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1.0 DESCRIPTION OF THE MACHINE

2.1 OPERATING PRINCIPLES

THE MACHINE MUST BE USED BY ONE OPERATOR ONLY!

IT IS STRICTLY FORBIDDEN TO DO ANY WELDING WORK ON THE

2.2 MAIN COMPONENTS

The main parts composing the machine are:

2.3 ENVIRONMENTAL CONDITIONS

The machine does not require a particular environment, although it is necessary to

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 9 of 87

Always make sure the machine is protected from weather

2.6 NOISE EMISSIONS

CASE 1 (HR4W 3120N )

CASE 2 (HR4W 306A, HR4W 332E, HR4W 126P )

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 10 of 87

2.7 TECHNICAL DATA

The equipment includes:

2.9 SUPPLIES ON DEMAND

At the customer's request, it is possible to receive the following components:

2.9.1 CENTRAL SUPPORT

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 11 of 87

2.9.2 LATERAL SUPPORT

SINGLE LATERAL GROUND-BASED SUPPORT

The side ground-based support (or arm) is delivered separately.

Via dell’artigianato, 30 S. Albano Stura 12040 (CN) ITALY Page 12 of 87

In addition to the number of the support, which should be used as identification

Never overload the support, because this would damage

2) The support is not fastened to the machine so as to allow it different positions,

USE OF THE LATERAL SUPPORT