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Main Equipment Master-3

 Video demonstration of the machine "Master 3"

 

Master-3 specifications

Characteristics Description
Working shaft speed 15,0 rpm
Direction of working shaft rotation Reversible
Electric motor power 1,1 kW
Power circuit current 380/ 220V, 50 Hz
Overall dimensions, length*height*width 380*395*694 mm
Machine weight ~95/105 kg
 

Cost of machine including delivery is calculated on request. If additional devices are needed, please specify the scope of supply as well as the city and country of delivery. Send your requests to oooman@mail.ru oooman@mail.ru

Scope of supply Photo Rolled stock, mm
■ square
● round
▬ strip
□ shaped tube
○ tube
..........Комплектации..........

 

380V

 


 

220V


 

Mega template – production of scrolls from 600 mm long and curl width from 200 to 350 mm with flattened and non-flattened ends ■ 8,10, 12, 14
● 6, 8, 10, 12, 14, 16* 
▬ 20х4,25х4
□ 10, 15*
+ +
Big assembly template – production of scrolls from 210 mm long 210 mm with flattened and non-flattened ends ■ 8,10, 12, 14
● 6, 8, 10, 12, 14, 16*
▬ 20х4,25х4
□ 10, 15*
+ +
Medium template – production of rolls from 200 mm long with flattened and non-flattened ends 03LS ■ 8,10, 12, 14
● 6, 8, 10, 12, 14, 16*
▬ 20х4,25х4
□ 10, 15*
+ +
Small template – production of rolls from 140 mm long with flattened and non-flattened ends ■ 8,10, 12, 14
● 6, 8, 10, 12, 14, 16*
▬ 20х4,25х4
□ 10, 15*
+ +
Big faceplate – production of rings with 120 mm diameter 05PB ■ 8,10, 12, 14
● 6, 8, 10, 12, 14
▬ 20х4, 25х4
□ 10, 15
+ +
Small faceplate – production of 90 mm diameter rings 06PM ■ 8,10, 12, 14
● 6, 8, 10, 12, 14
▬ 20х4, 25х4
□ 10, 15
+ +
Shaped tube clamp – production of longitudinal twisting, spiral-cone item 07Z
□ 10, 15 + +
Support for longitudinal twisting 08K ■ 8,10, 12, 14
▬ 20х4, 25х4
□ 10, 15
+ +
Set of rolls – making of bends, arcs (set: 1 central, 2 lateral) ■ 8,10, 12, 14, 16, 18, 20, 22, 24
● 6, 8, 10, 12, 14, 16, 18, 20, 22, 24
▬ 20х4, 25х4
□ 10, 15, 20, 25, 30 
+ +
Set of rolls for bending strips on edges (set: 1 central, 2 lateral)
 
▬ 20*4, 25*4, 40*4 + +
Additional equipment (optional)
Set of rolls for bends and arcs made of hollow tube  available tube size is up to 32
Turn-in device* *Making of element with flattened end

*Making of element with flattened end

 

.

LIMITED LIABILITY COMPANY
MAN
UNIVERSAL MACHINE FOR FORGING ITEM PRODUCTION
 
 
MASTER-3
Technical Certificate
 
 
ZARECHNYY
 
 
Introduction
Dear customer,
Thank you for the trust you have placed in us by purchasing our Master machine. This manual is designed for owners and service personnel to ensure reliable startup and trouble-free operation of the machine and its maintenance. Please pay attention to the information of the technical certificate and related documents. Please completely read the safety instructions on operations connected with the manufacture of forging items. Follow our instructions carefully to achieve maximum life and performance of your machine.
 
1. Certificate of compliance
 
We responsibly declare that this product meet the TU 3826-002-83434575-2014
specifications.
 
2. LLC "MAN" warranty conditions
Limited liability company "MAN" is committed to ensure its products meet the high requirements of customers for quality and reliability. 
LLC "MAN" guarantees the owner of the new machine that each product is free from defects in material and working. 
The warranty period is 12 (twelve) months for mechanical parts and component tools for hot and cold forging (dies. templates, rolls, rollers, clamps, faceplates, etc.) from the date of Equipment transfer to the Buyer.
The warranty is not applicable:
- if the Equipment or its components became out of service due to failure to observe the rules of Equipment operation by the Buyer;
- for Equipment components subject to natural wear;
- if the Buyer made changes in the internal structure of Equipment components, mechanisms and assemblies not coordinated with the Supplier;
- in case of Equipment damage as a result of the force majeure events, including deluge, flood, fire, fall, explosion, accident, etc.;
The warranty period starts from the date of sale to the first Buyer.
 
3. Safety measures when operating the machine
 
3.1. Intended use 
 
The Master-3 machine is designed exclusively for producing forging items (decorative ironwork) of general purpose steels mainly St. 0-3 and rolled steel sizes specified in the manual for each operation separately.
Production of forging items of other steels is not allowed. It can only be performed upon the consultation with the machine manufacturer.
The intended use also includes compliance with the instructions and maintenance provided by the manufacturer.
The machine must be served by the persons who are familiar with its operation and maintenance and warned of the potential hazards. 
Take into account generally accepted rules for forging equipment operation along with the safety instructions contained in the operating instructions and special requirements applicable in your country.
Every deviating use of the Equipment is considered as improper one and the manufacturer is not liable for damages resulted from it. The user takes responsibility in this case.
 
3.2. General safety instructions
 
Forging machines are dangerous in case of unqualified handling. Therefore, it is required to comply with existing safety regulations and the following instructions.
Read and fully understand all the instructions before you begin to install and operate the machine.
Keep the instruction manual near the machine, protect it from dirt and moisture and pass it to the new machine owner.
It is not allowed to make any changes, additions and rebuilding to the machine.
Make a visual inspection of the machine daily before switching it on.
Wear tight-fitting clothes.
Take off jewelry, rings and watch.
The machine must be installed so that to provide enough space for maintenance and workpiece feeding.
Keep up the good lighting.
Make sure that the machine stands steadily on a solid and flat surface.
Ensure there is no wiring that prevent the proper operation process and pose tripping hazard.
Keep the work area free from interfering workpieces and other items.
Be careful and concentrated. Take your work seriously.
Never operate the machine under the influence of psychotropic agents, such as alcohol and drugs. Take into account that medications can also cause adverse effects on your condition.
Do not allow children and unauthorized persons to enter the working area.
Do not leave the running machine unattended.
Unplug the machine before leaving the workplace.
Do not use the machine near the storage of flammable liquids and gases.
Do not use the machine in damp areas, don’t expose it to rain.
Work only with tools and devices installed on this machine.
Remove all tools and devices from the machine and work areas before starting the machine.
Remove obtained items only with the machine stopped.
Do not climb on the machine.
Only qualified electricians must work with electrical equipment.
Replace any damaged power cable immediately.
Keep your fingers at a sufficient safe distance from rotating parts.
Check the reliability of the workpiece clamp before operation.
Perform measurement and adjustment works only when the machine is de-energized. Readjustment, setting up and cleaning works must be performed only when the machine is fully stopped and the plug is disconnected. 
 
3.3. Other hazards
 
Some residual risks present even when using the machine in accordance with the instructions:
The risk of injury from the rolled stock processed.
The risk of electric shock from an incorrectly routed cable.  
 
4. Machine specifications
 
4.1. MASTER-3 technical data
 
Overall dimensions of the machine:
Length………………………………………………………………………………...……380 mm
Width………………………………………………………………………………………395 mm
Height…………………………………………………………………………...…………694 mm
Tool interface of the
1st working zone (shaft diameter)..……………………………………………………….…35 mm
Tool interface of the
2nd working zone (size between hole centers)……………………………………...……….45 mm
 
Stroke of roll guide rollers………………………………………………………………..95 mm
 
Installation position of folding roller bracket ……………………………………….……………3
 
Rotation frequency of machine working shaft ………………………………………..……15 rpm
 
Main drive capacity:
220 V electric motor …………...……………………………………………………….….1.1 kW
380 V electric motor ...……………………………………………………………………..1.1 kW
Main drive frequency:
220 V electric motor ………………………………………………………………..……1000 rpm
380 V electric motor ……………………………………………………………..………1000 rpm
Working current frequency……………………………………………………….………….50 Hz
 
 
Connecting cable………………………………………………………………………… 4*4 PVS
Machine weight……………………………………………………………………………..105 kg
 
4.2. Scope of supply
Basic kit:
Devices and fasteners:
- bracket (Part No. M2051) – 1 piece;
- pin (Part No. M2053) – 1 piece;
- stud (Part No. M20513) – 2 pieces;
- screw (Part No. M20535) – 2 pieces;
- stud (Part No. M20545) – 2 pieces;
- folding roller (Part No. M205SB16) – 1 piece;
- nut M12-6N GOST 5915-70 – 2 pieces;
- nut M16-6N GOST 5915-70 – 2 pieces;
- washer S. 12 GOST 11371-78 – 2 pieces;
- washer S. 16 GOST 11371-78 – 2 pieces.
Devices for longitudinal twisting:
- fixture (Part No. M205SB4) – 1 piece;
- retention bushing (Part No. M205SБ7) – 1 piece;
- bracket (Part No. M305SБ2) – 1 piece;
- ram (Part No. M305SБ3) – 1 piece
Rolling devices:
- central roller (Part No. M3055) – 1 piece
Ring winding devices:
- stud (Part No. M20550) – 1 piece;
- screw (Part No. M20556) – 1 piece;
- face plate (Part No. M20611) – 1 piece;
- face plate (Part No. M20612) – 1 piece;
- retaining washer (Part No. M20613) – 1 piece
Spiral winding devices:
- template (Part No. M206SB1) – 1 piece;
- template (Part No. M206SB2) – 1 piece;
- assembly template (Part No. M206SB5) – 1 piece;
- mega template (Part No. M206SB6) – 1 piece
Devices for point-down strip rolling:
- bushing (Part No. M20579) – 2 pieces;
- central roller (Part No. M3056) – 1 piece
 
Additional kits:
Tools for “Goose feet” turning-in:
- tail (Part No. М2068) – 1 piece;
- axle (Part No. М2069) – 1 piece;
- screw (Part No. М20610) – 1 piece;
 
4.3. Description
 
Fig. 4.1. General view of Master-3 machine
 
1 – machine table ; 2 – electrical cabinet; 3 – push-button station; 4 – indicator;  5 – circuit breaker;  6 – roll module stud nut; 7 – nut;  8 – roll module stud; 9 – roller; 10 – bushing; 11,12 – mounting plate; 13 – bushed flange; 14- electric motor.
 
 
 
 
5. Transportation and commissioning
 
5.1. Transportation and installation
 
The machine is shipped enclosed on a pallet.
Any vehicle can be used for transportation. Protect the machine from tipping over. 
The machine can be installed both indoors and outdoors in favorable conditions (t +5?...+45? without precipitations).
Installation diagram: See Fig. 5.1 and 5.2.
 
 
Fig. 5.1. Diagram for machine installation on the workbench (work table) 
                               Workbench sizes are approximate. The workbench must be securely fixed. 
 
 
Fig. 5.2. Diagram for machine installation on the rigid support surface
 
5.2. Installation
 
If you found any damages due to transport when unpacking, inform your seller immediately, do not run the machine!
Please dispose the package in accordance with the environmental requirements.
Remove the protective transport lubricants with kerosene, diesel or mild solvents.
Unscrew the bolts fixing the machine to the pallet.
Screw the mounting bolts to frame nuts.
 
The gearbox is supplied with an air hole plug. This plug must be placed in a required position after machine transportation and installation. 
 
Leveling
Use a level to install the machine evenly.
Frame length error is ~1..3/300 mm
 
5.3. Connection to electric circuit
 
The connection to circuit made by the customer and power cables used must comply with instructions. Circuit voltage and frequency must meet the parameters specified in the machine technical certificate.
A protective device installed by the customer must be rated at 16 A current.
Qualified electricians only must connect and repair electrical equipment. 
Electrical connection is performed to the terminal board located in the electrical cabinet or connecting cable plug depending on the scope of supply. 
Machine circuit diagram: Appendix 1.
 
5.4. Commissioning
 
Before machine commissioning, check all clamping devices and workpiece fixture (see Section 6).
The machine is equipped with the circuit breaker and circuit current indicator. Electrical equipment is switched using the circuit breaker with the circuit current indication.  
Output shaft rotation by the electric motor is set by “FORWARDS” AND “BACKWARD” buttons. The motor runs only when one of the buttons is pressed. 
 
Fig. 5.6. Push-button station
 
5.6. Machine run-in
 
Give the gearbox some time for break-in. 
Do not operate the machine too intensively during the first 8 hours. 
 
6. Machine operation
 
6.1. Longitudinal twisting operations
 
6.1.1. Longitudinal twisting of solid square stock 
It is required to install devices envisioned for this operation (see. Fig. 6.1.)
 
 
 
Fig. 6.1. Longitudinal twisting devices
1 – MASTER-3 machine ; 2 – bracket; 3 – ram; 4 – fixture ; 7 – screw; 11 – М16 bolt, 12 – washer. 
 
Cut the metal workpiece. 
Set rolled stock size with a gap in fixture 4.
Set the size of longitudinal twisting, i.e. set ram 3 in a required position at bracket 2 and fix it with the ram bolt.
Set the workpiece in fixture 4.
Fix the workpiece with ram bolts 3.
Press the “FORWARD” or “BACKWARD” button and hold it until the required item is obtained. 
Press the button that is reverse to working one and turn the bushing of free fixture 4 at a slight angle. 
Remove the item in a reverse order.
Note: DO NOT OVERTWIST THE WORKPIECE, IT MAY BRAKE! 
 
6.1.2. Longitudinal twisting of hollow square stock 
It is required to install devices envisioned for this operation (see. Fig. 6.2.)
 
 
Fig. 6.2. Longitudinal twisting tools for hollow square stock
1 – MASTER-3 machine ; 2 – bracket; 3 – ram; 4 – fixture ; 7 – screw; 8 – retention bushing; 11 – bolt, 12 – washer. 
 
Cut the metal workpiece. 
Set rolled stock size with a gap in fixture 4. 
Set rolled stock size with a gap in retention bushing 8.
Set the size of longitudinal twisting, i.e. set ram 3 in a required position at bracket 2 and fix it with the ram bolt.
Press the “FORWARD” or “BACKWARD” button and hold it until the required item is obtained. 
Press the button that is reverse to working one and turn the bushing of free fixture 4 at a slight angle. 
Remove the item in reverse order.
 
 
 
Note: DO NOT OVERTWIST THE WORKPIECE, IT MAY BREAK!
 
Hollow section can be twisted only at 1.5…2 turns, further twisting causes collapsing on hollow section. 
 
6.1.3. Making a cone-shaped item
It is required to install devices envisioned for this operation (see. Fig. 6.2.)
Cut four workpieces of equal length (?170-250 mm) from 8х8 square stock, or O 8 mm round one. 
Put them together so that they make a square. 
Weld ends and grind them to a square of 16х16 mm section maximum (See Fig. 6.3.)
   
 
Fig. 6.3. Workpiece for making a cone-shaped item
 
Set rolled stock size with a gap in fixture 4. 
Set rolled stock end size with a gap in retention bushing 8.
Put workpiece in fixture 4 and retention bushing 8.
Press the “FORWARD” or “BACKWARD” button and hold it until 1.5 turn twist is made.
Press the button that is reverse to working one and hold it until the item opens (about 2 turns).
Press the “FORWARD” or “BACKWARD” button and turn the bushing of free fixture 4 at a slight angle.
Remove the item in reverse order.
 
6.2. Rolling operations
 
The rolling method consists in periodical closing of workpiece ends by guide rollers through tightening of work module nuts (three nut turns in one pass are optimal). 
 
6.2.1. Rolling of solid and hollow section, strip steel 
It is required to install devices envisioned for this operation (see. Fig. 6.4.)
             
Fig. 6.4. Rolling devices
1- MASTER-3 machine; 4 – screw; 5 – central roller.
 
Cut the metal workpiece.
Adjust guide rollers towards central roller 5 by turning module nuts clockwise or counterclockwise. The distance from the lowest point of central roller to the upper points of guide rollers must be equal to the workpiece size. 
 
6.2.2. Point-down strip rolling
It is required to install devices envisioned for this operation (see. Fig. 6.5.)
                
Fig. 6.5. Rolling devices
1 – MASTER-3 machine; 4 – screw; 8 – bushing; 9 – central roller.
 
Cut the metal workpiece.
Adjust guide rollers towards central roller 9 by turning module nuts clockwise or counterclockwise. The distance from the lowest central roller point to the upper points of guide rollers must be equal to the workpiece size. 
Workpiece installation: install the strip steel in the groove of bushing 8 and central roller 9. 
 
6.3. Ring winding operation
 
6.3.1. Winding of 118 mm ID rings
It is required to install devices envisioned for this operation (see. Fig. 6.6.)
    
 
Fig. 6.6. Ring winding devices
1 – folding roller; 2 – MASTER-3; 5 – bracket; 6 – pin; 7 – stud; 8 – stud; 9 – stud; 10 – screw; 11 – face plate; 12 – thrust washer; 15 – M12 nut; 16 – M16 nut; 17 – washer; 18 – washer. 
 
Cut the metal workpiece.
Set the workpiece against thrust washer 12 and screw 10, and install the second end on folding roller 1.
Press the “FORWARD” button and hold it until rings are fully wound (maximum number of turns when winding is 3-4). 
Press the “BACKWARD” button to turn the workpiece at a slight angle in the opposite direction. 
Remove the workpiece.
 
6.3.2. Winding of 75 mm ID rings
It is required to install devices envisioned for this operation (see. Fig. 6.7.)
 
     
Fig. 6.7. Ring winding devices
1 – folding roller; 2 – MASTER-3; 5 – bracket; 6 – pin; 7 – stud; 8 – stud; 9 – stud; 10 – screw; 14 – face plate; 12 – thrust washer; 15 – M12 nut; 16 – M16 nut; 17 – washer; 18 – washer. 
 
Cut the metal workpiece.
Set the workpiece against thrust washer 12 and screw 10, and install the second end on folding roller 1.
Press the “FORWARD” button and hold it until rings are fully wound (maximum number of turns when winding is 3-4). 
Press the “BACKWARD” button to turn the workpiece at a slight angle in the opposite direction. 
Remove the workpiece.
 
6.4. Spiral winding operations
 
A tool for spiral winding of the bar stock end(s) is selected depending on the workpiece required.
 
Table 1. The list of tools and woklpieces: 
Tool Workpiece
Small template Roll size 200; twisting of the bar stock end
Medium template Roll size 200; twisting of the bar stock end
Assembly template Scroll; twisting of the bar stock end
Mega template Mega scroll, twisting of the bar stock end
 
Cut the bar to a required length according to Tables 1, 2. 
Workpiece requirements:
1.) Use Steel 0 - 3 only.
2.) Rolled stock – shaped tube, round or square bar, strip.
1.) Workpiece end – rolled stock section, crumpled ("goose foot", "fishtail"). 
 
Table 2. Workpiece sizes
Workpiece Workpiece size
With claws Without claws Shaped tubes
Mega-scroll 2400 mm 2500 mm 2500 mm
Big scroll 750 mm 850 mm 980 mm
Medium roll 500 mm 600 mm 750 mm
Small roll 400 mm 500 mm 600 mm
The smallest roll 380 mm
 
Note: The dimensions in the table are approximate and obtained empirically. 
 
6.4.1. SMALL ROLL production, working with small template 
It is required to install devices envisioned for this operation (see. Fig. 6.8.)
Cut the metal workpiece.
Press the “FORWARD” and “BACKWARD” buttons to install the initial template position so that the bar stock could freely enter the template slot horizontally. 
Put the workpiece in the template slot. 
Press the “FORWARD” button while supporting the free part of the workpiece by hand, so that the free workpiece part is placed on the support roller in the plain of template rotation when winding.
Warning!
For ease of workpiece installation and removal during operation, leave a small clearance when setting template thrust screws according to the corresponding workpiece end width.  
Spiral winding operations for big roll, curls and scrolls are the same. Refer to Fig. 6.8.-6.11 for device installation diagram.
 
   
Fig. 6.8. Devices for small roll production
1 – folding roller; 2 – small template; 3- MASTER-3; 6 – outrigger bracket; 7 – pin; 8– stud; 9 – stud; 17 – M12 nut; 18 – M16 nut; 19,20 – washer.
            
 
Fig. 6.9. Devices for big roll production
1 – folding roller; 11- medium template; 3- MASTER-3; 6—outrigger bracket ; 7 – pin  8– stud; 9 – stud; 17 – M12 nut; 18 – M16 nut; 19,20– washer.
 
       
Fig. 6.10. Devices for scroll and curl production 
 1 – folding roller; 12- big assembly template; 3- MASTER-3; 6 – outrigger bracket; 7 – pin; 8,9 – stud; 17 – M12 nut; 18 – M16 nut; 19,20– washer.
 
     
Fig. 6.11. Devices for big curl production, working with mega template
1 – folding roller; 13 – mega template; 3 – MASTER-3; 6 – outrigger bracket; 7 – pin; 8,9 – stud; 17 – M12 nut; 18 – M16 nut; 19,20– washer.
 
 
Warning!
Prior to working with mega template make a workpiece on the assembly template (initial curl). 
Warning!
Watch the outrigger bracket position before spiral winding operations. 
 
6.5. Curl turning-in operation 
 
 
 
            
 
Fig. 6.12. Devices for curl turning-in
1 – folding roller; 2- MASTER-3; 5 – outrigger bracket; 6 – pin; 7-stud; 8 – tail; 9 – bushing; 10 – screw; 13 – washer;  14 – M16 nut.
 
The turn-in device is used for final turning of scroll ends after “Goose feet” operation. 
Procedure of item end turning-in:
1) Install additional devices as shown in Fig. 6.12.
2) Set the curl into the turn-in device. 
3) Press the “FORWARD” button and hold it until the scroll end is curled as required. 
4) Press the “BACKWARD” button to ease workpiece pressure on the thrust roller. 
7. Control and maintenance
General instructions
The machine must be secured against unintentional switching on before maintenance and cleaning.
Disconnect the mains plug and turn off the circuit breaker!
Check the following during the machine operation: 
7.1. Integrity of grounding cables and power cable – daily;
7.2. Security of machine actuator fastening – daily; 
7.3. Cable insulation resistance (2.5 M? minimum) – twice a year; 
7.4. Oil level control (NMRV gearbox technical certificate) – every six months.
 
Clean the machine at regular intervals. 
Clean rotating fasteners and threaded holes from scale and dirt periodically. 
Qualified electricians only must connect and repair electrical equipment. 
 
8. Troubleshooting
 
Electric motor not running:
No current – check circuit breaker activation, check mains current. 
 
Faulty electric motor, buttons, circuit breaker, contactors or cables: call for electrician. 
 
Master-3 is a compact and efficient machine for decorative ironwork. 
 
This universal motorized forging machine is designed for making different forging elements and various rolled stock: square, strips, circles and shaped tubes. The machine performs cold forging, spiral winding, longitudinal bar twisting, forge rolling, ringing operations.
 
Master-3 is an optimal and efficient solution for both existing enterprises and starting your own forging business. The machine makes a lot of various elements and requires not much investment. 
 
THE MASTER-3 FORGING MACHINE is suitable even for amateurs, as far as the operation is simple and comfortable, and does not require high qualification as a forger. 
Master-3 is a good alternative to manual tools. It has the following advantages:  
  1. You get a highly efficient electric machine that costs like manual equipment. It allows performing all basic operations of cold forging of large rolled stock. 
  2. Two work areas make Master-3 a universal machine easy in operation.
  3. Connection to in-home circuit.
  4. The machine is available in 220 V and 380 V power versions, so you will have no problems with its connection. 
  5. Modern energy-saving technology provides power intake not more than of an electric kettle. 
  6. Ease of operation. Reliable and simple design allows to operate the equipment in non-prepared spaces without workpiece processing before its clamping on the machine.
  7. Small dimensions ensure easy machine transportation. 
Increased capacity. The machine works with two workpieces simultaneously and has an optimal working shaft speed for fast operation.
 

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