Valley Flashing Roll Forming Machine User Manual | Setup, PLC Controls & Operation Guide

Valley Flashing Roll Forming Machine Manual

Complete Setup, Operation, Controls and Production Guide

Introduction

This Valley Flashing Roll Forming Machine Manual provides a complete guide for safely setting up, operating, and maintaining a roll forming machine used to produce valley flashing profiles.

Valley flashing is a critical roofing component installed where two roof slopes meet. It directs water away from the roof structure and prevents leaks in high-flow drainage areas.

Valley flashing is widely used in:

  • residential roofing systems
  • metal roofing installations
  • commercial roofing systems
  • steel buildings
  • agricultural structures

Valley flashing profiles help:

  • channel rainwater efficiently
  • prevent water infiltration
  • protect roof structure joints
  • improve roof durability

Common valley flashing types include:

  • open valley flashing
  • closed valley flashing
  • W-valley flashing
  • custom deep valley profiles

This manual explains:

  • loading steel coil onto the uncoiler
  • preparing and feeding strip into the machine
  • aligning entry guides and roll forming stations
  • programming flashing lengths
  • operating PLC controls and jog systems
  • testing hydraulic cutting systems
  • inspecting finished valley flashing
  • troubleshooting production issues

This manual is intended for:

  • roll forming machine operators
  • roofing manufacturers
  • sheet metal fabrication companies
  • steel building manufacturers
  • maintenance technicians

1. Machine Overview

A Valley Flashing Roll Forming Machine forms flat steel strip into valley flashing profiles used in roof drainage systems.

The machine gradually bends the steel strip through a sequence of roll forming stations to create the required valley shape.

Valley flashing is installed at roof intersections where water flow is concentrated, making accuracy and consistency critical.

Applications include:

  • residential roofing
  • metal roofing systems
  • commercial roof drainage
  • industrial roofing
  • steel structure roofing

Typical Materials Processed

Common materials include:

  • pre-painted steel coil
  • galvanized steel
  • galvalume steel
  • aluminum coil

Typical Material Thickness

0.40 mm – 0.70 mm

Typical Production Speed

15 – 30 meters per minute

Production speed depends on:

  • valley profile depth
  • material thickness
  • machine configuration

2. Typical Machine Layout

A typical valley flashing roll forming production line includes:

  • Hydraulic Uncoiler
  • Entry Guide System
  • Roll Forming Stations
  • Encoder Length Measuring System
  • Hydraulic Cutting System
  • PLC Control Panel
  • Runout Table or Stacker

Material flow through the machine:

Steel Coil → Entry Guides → Roll Forming Stations → Encoder → Hydraulic Cutoff → Finished Valley Flashing

3. Safety Before Operating the Machine

Operators must perform safety checks before starting production.

Pre-Start Safety Inspection

Before starting the machine ensure:

  • emergency stop buttons function properly
  • machine guards are installed
  • hydraulic hoses are secure
  • electrical cabinets are closed
  • no tools or debris are inside the machine

Required Personal Protective Equipment

Operators should wear:

  • safety glasses
  • steel toe boots
  • gloves for handling sheet metal
  • hearing protection

Important Safety Rules

  • never reach into roll forming stations during operation
  • never stand directly in front of moving strip
  • never remove guards while machine is running
  • stop machine before adjustments

4. How to Load Steel Coil onto the Uncoiler

Step-by-Step Procedure

  1. Stop the roll forming machine completely.
  2. Retract the uncoiler mandrel.
  3. Lift the coil using forklift or overhead crane.
  4. Position the coil in front of the mandrel.
  5. Slide the coil onto the mandrel.
  6. Expand the mandrel until the coil is secured.
  7. Center the coil evenly.
  8. Install hold-down arm if available.
  9. Adjust uncoiler brake tension.

What to Watch For

  • coil not centered
  • coil slipping on mandrel
  • excessive brake pressure
  • loose mandrel expansion

Incorrect loading may cause strip tracking issues and flashing defects.

5. Preparing the Coil Leading Edge

Before feeding strip into the machine the coil edge must be prepared.

Procedure

  1. Carefully remove steel banding.
  2. Prevent sudden coil expansion.
  3. Inspect the first 300–500 mm of strip.
  4. Cut away damaged material.
  5. Square the leading edge.
  6. Remove burrs if necessary.

Why This Step Matters

Damaged strip edges can cause:

  • feeding problems
  • roller scratches
  • machine jams
  • poor flashing accuracy

6. Threading the Coil Through the Machine

Procedure

  1. Open entry guides fully.
  2. Feed strip manually into the first roll station.
  3. Use jog mode to slowly move strip forward.
  4. Continue feeding through roll forming stations.
  5. Guide strip through cutting section.
  6. Feed strip onto runout table.

Safety Warning

Never place hands between rotating rolls during operation.

7. Aligning and Centering the Strip

Proper strip alignment ensures accurate valley profiles.

Procedure

  1. Observe strip entering first roll station.
  2. Adjust entry guides left or right.
  3. Ensure strip runs parallel to machine centerline.
  4. Maintain equal clearance between guides.
  5. Run machine slowly to observe strip tracking.

Signs of Poor Alignment

  • profile twisting
  • uneven valley depth
  • strip drifting sideways
  • excessive guide contact

Correct alignment ensures consistent flashing quality.

8. Complete Valley Flashing Machine Setup Parameters

Material Type: Pre-painted steel / galvanized steel
Material Thickness Range: 0.40 – 0.70 mm
Coil Width: 300 – 700 mm depending on profile
Coil Weight: Up to 3 tons
Coil Inner Diameter: 450 – 520 mm
Entry Guide Clearance: Coil width + 1–2 mm
Forming Stations: 8 – 14 stations
Machine Speed (Setup): 5 – 10 m/min
Machine Speed (Production): 15 – 30 m/min

Roll Gap Setup

Roll gap should be set to:

Material thickness + 0.03–0.05 mm clearance

Example:

Material thickness = 0.50 mm
Recommended roll gap = 0.53 mm

Incorrect roll gap may cause:

  • flashing distortion
  • roller wear
  • inaccurate profile

9. PLC Control System Overview

Modern valley flashing machines use a PLC touchscreen control system.

The PLC controls:

  • machine start and stop
  • flashing length programming
  • production quantity
  • machine speed control
  • hydraulic cutting timing
  • encoder measurement

10. PLC Control Panel Functions

Typical controls include:

Start Button – starts machine
Stop Button – stops machine
Emergency Stop – emergency shutdown
Manual Mode – used during setup
Automatic Mode – used during production
Length Input – sets flashing length
Production Counter – tracks quantity

11. Jog Mode Operation

Jog mode allows controlled machine movement during setup.

Jog Procedure

  1. Switch machine to Manual Mode
  2. Press Jog Forward
  3. Machine moves slowly
  4. Release button to stop

12. Programming Valley Flashing Length

Procedure

  1. Enter required length on PLC
  2. Run test piece
  3. Measure finished length
  4. Adjust encoder calibration if needed

13. Encoder Length Measurement System

Length is measured using an encoder wheel.

Typical accuracy:

±1 mm

14. Hydraulic Cutting Operation

The hydraulic shear cuts valley flashing to programmed length.

Cutting sequence:

  1. Encoder measures length
  2. PLC activates hydraulic system
  3. Blade cuts flashing
  4. Product exits machine

17. Inspecting Finished Valley Flashing

Inspection checklist:

  • flashing length
  • valley depth
  • bend accuracy
  • straightness
  • surface finish
  • cut quality

18. Valley Flashing Production Troubleshooting Guide

Profile Twisting
Possible Causes: strip misalignment
Solution: adjust entry guides

Uneven Valley Depth
Possible Causes: roll misalignment
Solution: adjust roll stations

Surface Scratches
Possible Causes: dirty rollers
Solution: clean rollers

Incorrect Length
Possible Causes: encoder issue
Solution: recalibrate encoder

22. Valley Flashing Roll Forming Machine Technical Specifications

Forming Stations: 8 – 14 stations
Material Thickness Range: 0.40 – 0.70 mm
Production Speed: 15 – 30 m/min
Drive System: Chain drive or gearbox
Cutting System: Hydraulic cutoff
Control System: PLC touchscreen
Coil Weight Capacity: 2 – 3 tons
Coil Inner Diameter: 450 – 520 mm
Electrical Power Requirement: 380 – 480V three-phase

23. Best Operator Practices

  • inspect first flashing piece
  • monitor valley depth consistency
  • maintain strip alignment
  • keep rollers clean
  • stop machine if abnormal noise occurs

Proper operation ensures high-quality valley flashing and long machine life.

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