Bomar Ergonomic 320.250 DGS, Ergonomic 320.250 DG, Ergonomic 320.250 DGH Operating Instructions Manual

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Series Ergonomic

Ergonomic 320.250 DGS

Operating instructions

Before transporting and using the machine, please read the instructions thoroughly!

Seriové číslo / Serien Nummer / Serial Number ___________________

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Service and information

Your BOMAR dealer

Direct BOMAR contact:

BOMAR spol. s r.o.

Těžební 1236/1 62700 Brno Czech Republic, EU

telefon: +420 – 533 426 100 fax: +420 – 533 426 109 e-mail: info@bomar.cz www: http://www.bomar.cz

We are available:

Mondays to Fridays 700 – 1600

Version:

1.02 / Mar. 2010 rev. 1

BOMAR, spol. s r.o. © – Subject to modifications and amendments.

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

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Content

1. SAFETY NOTES ........................................................................ 7

1.1. Machine determination .......................................................................................................................................................... 9

1.2. Protective suit and personal safety ................................................................................................................................. 9

1.3. Safety notes for machine operator .............................................................................................................................. 10

1.4. Safety notes for the servicing and repairs ............................................................................................................... 10

1.5. Safety machine accessories .............................................................................................................................................. 11

1.5.1. Total Stop .................................................................................................................................................................. 11

1.5.2. Arm cover ................................................................................................................................................................. 11

1.5.3. Band saw cover ..................................................................................................................................................... 11

1.5.4. Saw band stretching and rupture inspection ................................................................................... 11

1.6. Safety notes for the cooling ............................................................................................................................................. 12

1.6.1. Instructions for first help ................................................................................................................................. 12

1.7. Umístění štítku stroje / Maschinenschild position / Position of machine label .............................. 12

1.8. Umístění bezpečnostních značek / Verteilung der Sicherheitszeichen / Position of safety

symbols .......................................................................................................................................................................................... 13

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2. MACHINE DOCUMENTATION ................................................15

2.1. Technická data / Technische Daten / Technical data ...................................................................................... 17

2.2. Rozměrové schéma / Aufstellzeichnung / Installation diagram ............................................................... 18

2.3. Popis / Beschreibung / Description ............................................................................................................................. 19

2.4. Transportation and stocking ............................................................................................................................................ 20

2.4.1. Conditions for transportation and stocking ....................................................................................... 20

2.4.2. Transport and stocking preparations ...................................................................................................... 20

2.4.3. Transport and stocking .................................................................................................................................... 20

2.4.4. Transportní schéma / Transport schema / Transport diagram ............................................ 21

2.5. Activation...................................................................................................................................................................................... 22

2.5.1. Machine working conditions ....................................................................................................................... 22

2.6. Band saw unpacking and assembling ....................................................................................................................... 22

2.6.1. Machine installing and levelling ................................................................................................................ 24

2.6.2. Machine disposal after lifetime ................................................................................................................... 24

2.6.3. Kotevní plan / Verankerungsplan / Grounding plan ..................................................................... 25

2.7. Electrical connection ............................................................................................................................................................. 26

2.7.1. Check the direction of the saw band...................................................................................................... 26

2.8. Filling of the cooling system ............................................................................................................................................ 26

2.9. Check machine function .................................................................................................................................................... 27

2.10. Saw band.......................................................................................................................................................................... 27

2.10.1. Saw band size ................................................................................................................................................. 27

2.10.2. Selection of the saw band tooth system....................................................................................... 27

2.10.3. Saw band running-in ................................................................................................................................. 27

3. MACHINE CONTROL ..............................................................29

3.1. Main switch ................................................................................................................................................................................. 31

3.2. Control elements ..................................................................................................................................................................... 31

3.2.1. Ergonomic 320.250 DGS without frequency converter .............................................................. 31

3.2.2. Ergonomic 320.250 DGS with frequency converter ...................................................................... 32

3.3. Machine control ....................................................................................................................................................................... 33

3.3.1. Cutting ........................................................................................................................................................................ 33

3.3.2. Setting of the material length ..................................................................................................................... 33

3.3.3. Cutting speed adjustment ............................................................................................................................. 34

3.3.4. Angular cut setting ............................................................................................................................................. 34

3.4. Material insertion ..................................................................................................................................................................... 35

3.4.1. Handling agent selection ............................................................................................................................... 35

3.4.2. Insertion ..................................................................................................................................................................... 35

3.4.3. Bundle material cutting ................................................................................................................................... 35 

4. MACHINE SERVICE ................................................................37

4.1. Saw band dismantling ......................................................................................................................................................... 39

4.2. Saw band installation ............................................................................................................................................................ 40

4.3. Saw band stretching and inspection .......................................................................................................................... 41

4.3.1. Saw band stretching .......................................................................................................................................... 41

4.3.2. Saw band inspection ......................................................................................................................................... 41

4.4. Adjustment .................................................................................................................................................................................. 42

4.4.1. Saw band petting ................................................................................................................................................ 42

4.4.2. Hard metal guides adjustment ................................................................................................................... 42

4.4.3. Guide cube adjustment ................................................................................................................................... 43

4.4.4. Brush adjustment ................................................................................................................................................ 43

4.4.5. Angular stops adjustments ........................................................................................................................... 44

4.4.6. Adjusting the limit switch of the saw band stretching ............................................................... 44

4.4.7. Saw frame lower position stop adjustment ....................................................................................... 45

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

4.4.8. Adjustment of the limit switch of saw frame lower stop point ............................................. 45

4.5. Cooling agents and chips disposal .............................................................................................................................. 46

4.5.1. Coolant device ins pection ............................................................................................................................. 46

4.5.2. Cooling liquid preparation¨ .......................................................................................................................... 46

4.5.3. Chips disposal ........................................................................................................................................................ 47

4.6. Greases and oils ........................................................................................................................................................................ 47

4.6.1. Gearbox oils ............................................................................................................................................................. 47

4.6.2. Lubricant greases ................................................................................................................................................ 48

4.6.3. Lubricatio n ............................................................................................................................................................... 49

4.6.4. Hydraulic oils .......................................................................................................................................................... 49

4.6.5. Hydraulic oil level check .................................................................................................................................. 50

4.6.6. Adjustment of a throttle valve .................................................................................................................... 50

4.7. Machine cleaning .................................................................................................................................................................... 51

4.8. Worn pieces replacement ................................................................................................................................................. 51

4.8.1. Hard metal guides replacement ................................................................................................................ 51

4.8.2. Saw band guiding rollers replacement ................................................................................................. 52

4.8.3. Round brush replacement ............................................................................................................................ 53

4.8.4. Stretching wheel replacement ................................................................................................................... 54

4.8.5. Driving wheel replacement .......................................................................................................................... 56

4.8.6. Cooling pump replacement ......................................................................................................................... 57

5. ZÁVADY / TROUBLESHOOTING ............................................ 59

5.1. Mechanical problems ........................................................................................................................................................... 61

5.2. Electric problems ..................................................................................................................................................................... 63

6. SCHÉMATA / SCHEMAS / SCHEMATICS ............................... 65

6.1. Elektrická schémata / Elektroschemas / Wiring diagrams – bez frekv. měniče / ohne

Frequenzumrichter / without frequency convertor – 3×400 V/50 Hz, TN-C-S ................................ 67

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6.2. Elektrické schema / Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F,

3×400 V TN-C-S ......................................................................................................................................................................... 71

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6.3. Elektrické schema / Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F,

3×400V TN-C .............................................................................................................................................................................. 74

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6.4. Elektrické schema / Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F,

3×230 V .......................................................................................................................................................................................... 78

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6.5. Hydraulické schéma Hydraulisches Schéma Hydraulic diagram .............................................................. 82

7. VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ / ZEICHNUNGEN FÜR BESTELLUNG DER ERSATZTEILE / DRAWING

ASSEMBLIES FOR SPARE PARTS ORDER ....................................... 83

7.1. Ergonomic 320.250 DGS ..................................................................................................................................................... 84

7.2. Kusovník / Stückliste / Piece list – Ergonomic 320.250 DGS ....................................................................... 85

7.3. Ergonomic 320.250 DGS ..................................................................................................................................................... 86

7.4. Kusovník / Stückliste / Piece list – Ergonomic 320.250 DGS ....................................................................... 87

7.5. Rameno / Sägerahmen / Saw arm .............................................................................................................................. 88

7.6. Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm ................................................ 89

7.7. Rameno / Sägerahmen / Saw arm ............................................................................................................................... 90

7.8. Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm ................................................ 91

7.9. Napínání / Spannung / Tensioning ............................................................................................................................. 92

7.10. Kusovník / Stückliste / Piece list – Napínání / Spannung / Tensioning ................................. 93

7.11. Vedení pásu / Sägebandführung / Belt guide ........................................................................................ 94

7.12. Kusovník / Stückliste / Piece list – Vedení pásu / Sägebandführung / Belt guide .......... 95

7.13. Vodící kostka / Führungsklotz / Guiding cube – 1 ................................................................................ 96

7.14. Vodící kostka / Führungsklotz / Guiding cube – 2 ............................................................................... 97

7.15. Konzola otočná/ Drehkonsole / Turnable consol ................................................................................. 98

7.16. Kusovník / Stückliste / Piece list – Konzola otočná / Drehkonsole / Turnable consol . 99

7.17. Svěrák / Schraubstock / Vice ............................................................................................................................ 100

7.18. Kusovník / Stückliste / Piece list – Svěrák / Schraubstock / Vice .............................................. 101

7.19. Válec zvedací / Hebezylinder / Liftink cylinder ..................................................................................... 102

7.20. Kusovník / Stückliste / Piece list – Válec zvedací / Hebezylinder / Liftink cylinder ....... 103

7.21. Podstavec / Untersatz / Base ............................................................................................................................ 104

7.22. Kusovník / Stückliste / Piece list – Podstavec / Untersatz / Base ............................................... 105

7.23. Ovládací panel / Bedienpult / Control panel ......................................................................................... 106

7.24. Kusovník / Stückliste / Piece list – Ovládací panel / Bedienpult / Control panel ............ 107

7.25. Chlazení / Kühlung / Cooling .......................................................................................................................... 108

7.26. Kusovník / Stückliste / Piece list – Chlazení / Kühlung / Cooling ............................................ 109

7.27. Stůl / Tisch / Table .................................................................................................................................................... 110

7.28. Kusovník / Stückliste / Piece list – Stůl / Tisch / Table ...................................................................... 111

7.29. Doraz / Anschlag / Stop piece .......................................................................................................................... 112

7.30. Kusovník / Stückliste / Piece list – Stůl / Anschlag / Stop piece ................................................ 113

7.31. Kartáč / Bürste / Brush .......................................................................................................................................... 114

7.32. Pružina / Feder / Spring ....................................................................................................................................... 115

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Bezpečnostní pokyny

Sicherheitshinweise

Safety notes

1. Safety notes

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Bezpečnostní pokyn

Sicherheitshinweise

Safety notes

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Bezpečnostní pokyny

Sicherheitshinweise

Safety notes

The operating instructions must be read by the person, who keeps in touch with the machine before transportation, installation, using, servicing, reparation, stocking or removal!

The operating instructions include relevant information. The operator must familiarise himself with the install and operation, safety notes and machine servicing, because reliability and service life must be reached. The operating instructions must avoid risks, which are linked to work on the machine. Before transporting and using of the machine, please read the instructions thoroughly!

1.1. Machine determination

The band saw Ergonomic 320.250 DGS is determined for cutting and shortening of rolled bars and drawn bars and profiles from steels, stainless steels, non-ferrous metals and plastics with cutting angles from -45° to 60°.

Combustible materials are excepted for cutting! Any other usage and operation outside this range are unauthorized and the manufacturer/supplier does not accept any responsibility for any damages resulting from such misuse. The operator has full responsibility!

The machine is equipped with safety and protective guarding for operator and machine protection. Nevertheless, this safety and protective guarding cannot prevent injury. Service personnel must read this chapter and comprehend it, before he starts to work on the machine. Always keep instructions about work safety! Service personnel must take into account other aspects of the risk, which refer to the ambient conditions and the material.

1.2. Protective suit and personal safety

Wear tight fitting overalls! Loose fitting clothes may be caught with machine parts

and cause serious injury.

Wear protective gloves! Material cuts and saw band have sharp edges and may cause serious injuries.

Wear protective shoes with non-skid soles! The unsuitable shoes may cause balance loss and following injury. Falling work pieces may cause serious injuries too.

Wear protective goggles! Chips and cooling liquid may damage your eyes.

Always wear ear protections! Most of the machines emit up to 80 dB and may

damage your hearing.

Do not wear jewellery and always tie back long hair! Moving machine parts can catch jewellery or loose hair and may cause serious injuries.

Operate the machine only when you are fit enough to work. Illnesses or injuries diminish concentration. Avoid machine work, which may compromise the safety of you and your colleagues!

Attention!

The operating instructions must be available at the machine! Keep the operating instructions in good condition!

Attention!

Consider the safety signs on the machine. Do not remove or damage them!

Attention!

Gloves you can use only at working material replacement (saw band)! The machine and accessories must be inactive! If the machine is running, you must not wear gloves! It is dangerous, because some parts of the machine can catch gloves!

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Bezpečnostní pokyn

Sicherheitshinweise

Safety notes

1.3. Safety notes for machine operator

Machine can be operated only by one person. Machine operator is responsible for presence of other persons by the machine.

Close covers before the machine starting and check, if the covers are not damaged. Damaged covers must be repaired or changed. Do not start the machine, if the cover is removed! Check, if the electric cables are not damaged.

• Do not hold the material for clamping to the vice and for cutting!

• Do not operate with the buttons and the switches on the control panel, when you

have gloves!

• For machine starting take care, that there is nobody in the working area of the

machine (it means in the working area of the vice, the saw band, the saw arm etc.).

• In no circumstances touch the rotating elements.

• Work on the machine only when the machine is in good condition!

• Check at least once in a shift, if the machine is not damaged. If the machine is

damaged, you must bring the machine in order and you must inform your superior!

• Keep your working area clean! Ensure sufficient lighting in the working area.

• Take off the spilt water or the oil from the floor and dry it. Do not touch the

cooling liquid with bare hands! Do not set the nozzle of the cooling liquid, when the machine is started on

• Do not remove the chips from the working area of the machine, when the

machine is started on!

• Do not use the compressed air for the machine cleaning or for the chips

removing!

• Use the protective instruments for chips removal!

1.4. Safety notes for the servicing and repairs

Switch off the main switch and lock it, before you start service work! Otherwise, there is possibility of hazardous machine starting.

Only qualified person can do the servicing and repairs. For parts changing, use only parts, which are identical with the originals. Otherwise, there is possibility of health hazard. Use only recommended type of the hydraulic oils and oils and lubricants!

Attention!

Machine can be operated by person older than 18 years! Machine can be operated only person physically and mentally fit for this activity

Keep instructions and orders about work safety!

Read the operating instructions, before you start to work on the machine! Keep the operating instructions in good condition!

Attention! Do not connect the machine to electricity if the covers are removed. Do not touch the electrical equipment.

Attention!

Only a qualified professional can carry out the servicing and repairs of the electric equipment! Take special care during the work with electrical equipment. High voltage shock can have fatal consequences! Always keep notes about work safety! Otherwise, there is possibility of heavy injury!

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Bezpečnostní pokyny

Sicherheitshinweise

Safety notes

Do not remove or do not lock the limit switches or safety equipments! Any use of the saw, accessories or machine parts other than that intended by the BOMAR, spol. s r.o. company is not permitted. The guarantee on this product will be afterward lost and BOMAR, spol. s r.o. takes no responsibility for caused damages.

1.5. Safety machine accessories

The machine is equipped with safety accessories. It protects the operator from injuries and the machine before damage. The safety accessories are blocking accessories, emergency switches and covers. Check once in a week the function of the safety accessories. If the safety accessories are functionless, you must stop work and repair or change the safety accessories.

1.5.1. Total Stop

TOTAL STOP button is used for emergency switching – off the machine in case defect

or health hazard. By pressing TOTAL STOP button is interrupted the supply of the electrical power.

If any damages or fault appears, immediately press TOTAL STOP button! Release the pressing button is possible by twisting of the upper part of the button.

1.5.2. Arm cover

If the cover is opened during operation, the limit switch is opened and the band saw is stopped. The band saw is not possible start in set mode.

The band saw is stated to the operation, when the cover is closed!

1.5.3. Band saw cover

It covers the visible area of the saw band from guiding cube to the frame.

Never turn-ON saw band when cover is not mounted!

1.5.4. Saw band stretching and rupture inspection

This device checks the saw band tension and causes immediate machine stop if the band incidentally ruptures.

Enhanced risk!

Do not come into or intervene in the cutting area. Otherwise, there is possibility of heavy injury.

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Bezpečnostní pokyn

Sicherheitshinweise

Safety notes

The device includes a limit switch. Its adjustment is described in chapter „Servicing and adjusting“. Check the switch carefully and periodically – adjust it if necessary.

1.6. Safety notes for the cooling

1.6.1. Instructions for first help

1. Pull off and safely remove polluted, soaked clothing.

2. For breathing, go out in the fresh air or look for first aid treatment.

3. Wash with water or use crèmes for contact with the skin.

4. Flush with water for eyes and look for first aid treatment.

5. For swallowing, drink a lot of water and induce vomiting. Look for medical help.

1.7. Umístění štítku stroje /

Maschinenschild position / Position of machine label

Attention!

 When handling cooling agents always wear hazardous

fluid-proof gloves!

 Wear protective goggles!  Cooling liquid can get in contact with your eyes and may

cause permanent severe injuries

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Bezpečnostní pokyny

Sicherheitshinweise

Safety notes

1.8. Umístění bezpečnostních značek /

Verteilung der Sicherheitszeichen / Position of safety symbols

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

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Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2. Machine

documentation

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Dokumentace stroje

Dokumentation der Maschinen

Machine documentation



Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2.1. Technická data /

Technische Daten / Technical data

Hmotnost stroje / Maschinengewicht / Machine weight:

• Hmotnost / Gewicht / Weight

372 kg

Rozměry stroje / Maschinengröße / Machine size :

• Délka / Länge / Lenght

• Šířka / Breite / Width

• Výška / Höhe / Height

1562 mm

900 mm

1255 mm

Elektrické vybavení / Elektrische Ausrüstung / Electical equipment:

• Napájení / Versorgungsspannun / Supply voltage

• Příkon / Gesamptschlusswert / Total Input

• Max.jištění / Max. Vorschaltsicherung / Max. Fuse

• Krytí / Schutzart / Protection

~ 3×400V, 50H z

1,7 kW

16 A

IP 54

Akustický tlak / Schalldruckpegel / Acoustic pressure:

• Ergonomic 320.250 DGS

Aeqv

= 59 / 65 dB1

Pohon / Atrieb / Drive:

• Typ / Typ / Type

• Výkon / Leistung / Output

• Jmenovité otáčky / Motornenndrehzahl / Nominal speed

TM 90-2/4S B5

1,1 / 1,5 kW

2800/1420 m/min

Chladící zařízení / Kühlmiteleinrichtung / Cooling equipment:

• Výkon / Leistung / Output

• Obsah nádrže / Volumen vom Kühlmittel / Capacity

0,09 kW

20 dm3

Rozměr pásu / Sägebanddimension / Band size:

2910×27(25)×0,90 mm

Řezná rychlost / Schnittgeschwindigkeit / Cutting speed:

without freq. converter: 40-80 m/min, with freq. converter: 20–120 m/min

Řezné rozsahy / Schnittbereiche / Cutting size:

0°

250 mm 320×190 mm 300×240 mm 240×240 mm

R 45°

220 mm 220×120 mm 190×240 mm 210×210 mm

L 45°

180 mm 200×100 mm 100×240 mm 160×160 mm

R 60°

130 mm 130×100 mm 130×100 mm 100×100 mm

Level of acoustic pressure:

Equivalent level of acoustic pressure A (noise) at operator position are L

Aeqv

=59 / 65 dB for speed

40 m.min

-1

/ 80 m.min-1. Mentioned values are levels of emission which doesn’t have to represent safe levels. Factors which influence real level of acoustic pressure on machine operator are: working place characteristics, cut material, saw band. These factors have significantly influence on acoustic pressure..

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2.2. Rozměrové schéma /

Aufstellzeichnung / Installation diagram

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Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2.3. Popis /

Beschreibung / Description

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2.4. Transportation and stocking

2.4.1. Conditions for transportation and stocking

Keep recommendations for the manufacturers for transportation and stocking! If the recommendations are not kept, damage can occur to the machine.

• Don’t use a forklift truck for handling the machine, if you do not have license for it!

• Don’t move under suspended loads! Fault in lifting device may cause serious

injury.

• Keep a safe distance from the machine during the transport.

• Temperature of the air from -25°C to 55°C, for a short term (max. 24 hours)

temperature of the air until 70°C

• Do not expose the machine to radiation (for example microwave radiation,

ultraviolet radiation, laser radiation, x-ray radiation). Radiation can cause problems with the machine function and deteriorating condition of the isolation.

• Take measures, to prevent damage by dampness, by vibrations and by shakes.

2.4.2. Transport and stocking preparations

Close the vice and thoroughly oil all blank surfaces.

Lower the saw frame to the lowest position.

Make sure to empty the machine of all traces of the cooling agent.

Fasten all loose parts securely to the machine.

Pack and wrap the control desk securely to avoid damage during transport.

Fix the stickers stating the minimum approximate machine weight to at least five well visible places.

2.4.3. Transport and stocking

The machine must be secured during transportation. Screw on the palette to the floor of the van or the trailer. Be careful that the machine is not damaged during transportation. Store the machine only under conditions mentioned in the manual, to avoid damage of the machine.

It is forbidden to handle the machine any other way, than it is written in this operating instructions, the machine can be damaged.

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Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2.4.4. Transportní schéma /

Transport schema / Transport diagram

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Dokumentace stroje

Dokumentation der Maschinen

Machine documentation

2.5. Activation

2.5.1. Machine working conditions

Keep the conditions of the manufacturer for machine operating! If recommendations are not kept, damage can occur to the machine.

The manufacturer warrants the correct function of the machine for these conditions:

• At temperature air from 5°C to 40°C, the temperature average during 24 hours

must not exceed over 35°C.

• At relative dampness of the air in the extend from 30% to 95% (not concentrate)

• Altitude lower than 1000 metres.

• Do not expose the machine to the radiation (for example microwave radiation,

ultra-violet radiation, laser radiation, x-ray radiation). Radiation can cause problems with the machine function and deteriorating condition of the isolation.

2.6. Band saw unpacking and assembling

Remove the packing from the machine and unpack all parts.

Component Description

Assembly of the control panel

Screw on the control panel with 4 screws to the pedestal.

Assembly of the hold-down lever..

Attention!

Switch off the main switch and lock it, before you start assembly! Otherwise, there is possibility of hazardous machine starting.

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Component Description

Hand wheel assembling

Take down the nut from holder of the hand wheel. Insert it to the hole on back side of the wheel and screw on the holder.

Length stop assembly

1. Take on the length stop to the hole on vice side.

2. Shift the length stop till the saw band (arrow 1)

and set the scale to the value „0“ (arrow 2).

3. Secure it with screw on the bottom side of the

vice.

Drainage metal plate installing

Install drainage metal plate on the backside of the band saw.

Lifting spring assembly

1. Lift the saw arm up.

2. Unscrew the screw and remove the washer from

the holder.

3. Put together the spring and draw bar. Put the

assembly on the holder and the console

4. Put the washer on the holder and screw on the

screw.

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2.6.1. Machine installing and levelling

Check the floor supporting capacity before machine installing. If the floor capacity does not agree with requirements, you must prepare the necessary base for the machine.

Minimal requirement:

machine weight –

Ergonomic 320.250 DGS – 372 kg

+ weight of accessories

+ maximum weight of material

• The machine must be levelled at the horizontal position. All feet of the machine

must touch with the floor after levelling

• The machine must be levelled by means of the calibrated spirit level. Spirit level is

put on the vice area. Set the roller conveyors according to the spirit level.

• For machine levelling, take care that there is sufficient available space for

operation, repair work, servicing of the machine and handling the material..

• The machine including appended parts and accessories must be visible from the

place of operation.

2.6.2. Machine disposal after lifetime

Blown out all service fluids (cooling liquid, hydraulic oil) into designated reservoir. Dismantle machine into separate parts and dispose them in accordance with valid directives.

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2.6.3. Kotevní plan /

Verankerungsplan / Grounding plan

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2.7. Electrical connection

Electrical parameters of the machine:

• Service voltage: ~ 3×400 V, 50 Hz, TN-C-S

• Total input / Max. fuse: 1,7 kW / 16 A

Before connecting switch off the main switch of the power supply circuit for the machine and ensure dry place when doing connecting works!

Service voltage must agree with the line voltage! Crosscut of the supply line must respond with rated current for max. machine load.

Connect the service cable of the machine on the clamps of the electric distribution.

In case the machine is connected with a direct connection, an extra main switch must be added which can be locked in zero position.

2.7.1. Check the direction of the saw band

After the machine has been successfully connected, briefly switch on the machine and put the driving engine of the band in the running position. The direction must be in accordance with the arrow direction on the saw band cover. In case the direction of the saw band does not match, two phases at the terminal strip must be switched.

2.8. Filling of the cooling system

Prepare the mixture of the water and the cooling liquid. Keep the concentration specified by manufacturer. Shift away the cover from the drainage hole. Fill the mixture of the water and the cooling liquid to the tank of the cooling system. Area of the tank for the cooling liquid is discovered from the chapter Technical data.

Let the drainage hole opened and with the sieve during operation, because it secures the right work of the cooling system. Filling the tank with the cooling liquid, take care that the liquid does not drip out of the tank and the tank does not overflowed.

Attention! Only a qualified professional must carry out the servicing and repairs of the electric equipment! Take special care

during work with electrical equipment. High voltage shock can have fatal consequences! Always keep notes about work safety.

Note:

The values of the crosscut of the conductor and the rated current are in the norms.

Note:

The socket with the fork can be used only at the machines with the rated current less than 16 A and total input less than 3 kW.

Attention!

In this case the extra main switch becomes primary and the main switch on the machine has only secondary function.

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2.9. Check machine function

Check, if the machine or some parts of the machine were not damaged during transport.

Check, if covers are installed and functional. Check by means of the Tenzomat if the saw band is correctly stretched. If it is necessary, you can stretch the saw band according to chapter Selection and replacement of the saw band. Values of the saw band stretching are on the Tenzomat. Switch on the main switch and check the motors and systems (saw band drive, hydraulic pump, cooling pump, chips conveyor).

Open and close the main vice. Turn the saw frame of the band saw from one outer position to other outer position. Raise the saw frame to the top position and drop the saw frame to the lowest position.

Start the machine with the cooling pump and let it run without load until the cooling system will be filled with cooling liquid. As soon as the cooling liquid starts to escape from the nozzles of the cooling system, the cooling system is ready for the operation. Carry one cycle of cutting without material. Check, if the machine runs with no irregularities. If all machine functions are right, the machine is ready for operation..

2.10. Saw band

Refit the saw band cover only after you have installed and tightened the saw band.

2.10.1. Saw band size

2910×27(25)×0,90 mm

2.10.2. Selection of the saw band tooth system

The manufacturers provide the saw bands with constant and variable tooth system. The important factor for selection of the tooth system is length of the cutting canal with respect to the size of the product

1. Constant tooth system – the saw band has parallel tooth pitch all over length. This

way is suitable for cutting of solid material.

2. Variable tooth system – tooth pitch is variable. Variable tooth system is used for

profiled materials and bundle cutting. Variable tooth pitch lowers vibration of the saw band, increases service life of the saw band and quality of the cutting area.

In tables, there are advised type of the tooth system depending on sizes and form of the cutting material.

Footnotes:

ZpZ – teeth number on one inch S – tooth with zero angle of the teeth K – tooth with positive angle of the teeth

Examples of the tooth system marking:

32 S – number „32“ means 32 teeth on one inch (that means constant tooth system), letter „S“ marks teeth with zero angle of the tooth.

4–6 K – number „4–6“ means 4 till 6 teeth on one inch (that means variable tooth system); letter „K“ marks teeth with positive angle of the teeth.

2.10.3. Saw band running-in

Running-in: Cut the material with the frame lowering reduced to 50% only. When

vibrations occur increase or decrease the band speed.

BOMAR for recommended Variable tooth system for band saw.

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When cutting small pieces run the band until approximately 300 cm2 of material has been cut. When cutting large pieces run the band for 15 minutes approximately. When the band has been run, increase the lowering-speed to normal speed. The running in of the saw band avoids micro-breaks on the cutting edges of new saw band ensuing from first excessive stress. This would decrease service life substantially. The optimal running in of the saw band produces ideal rounded cutting edges and therefore the conditions for an optimal service life.

Tables for teeth selection

SHAPED MATERIAL (Dp, S = mm)

Note: Table shows tooth system selection for cutting one piece of the profile. For cutting of more pieces of the profiles (bundle), you must think of the size of the wall as double size of the wall of one profile (that means, size „S“ equates to 2×S). In table, th ere are tooth systems constant and variable.

Size of the

wall

S [mm]

Tooth system (Z

Outer diameter of the profile D

[mm]

20 40 60 80 100 120

2 32 S 24 S 18 S 18 S 14 S 14 S 3 24 S 18 S 14 S 14 S 10–14 S 10–14 S 4 24 S 14 S 10–14 S 10–14 S 8–12 S 8–12 S 5 18 S 10–14 S 10–14 S 8–12 S 6–10 S 6–10 S 6 18 S 10–14 S 8–12 S 8–12 S 6–10 S 6–10 S

8 14 S 8–12 S 6–10 S 6–10 S 5–8 S 5–8 S 10 - 6–10 S 6–10 S 5–8 S 5–8 S 5–8 S 12 - 6–10 S 5–8 S 5–8 S 4–6 K 4–6 K 15 - 5–8 S 5–8 S 4–6 K 4–6 K 4–6 K 20 - - 4–6 K 4–6 K 4–6 K 3–4 K 30 - - - 3–4 K 3–4 K 3–4 K 50 - - - - - 3–4 K

Size of the

wall

S [mm]

Tooth system (Z

Outer diameter of the profile D

[mm]

150 200 300 500 750 1000

2 10–14 S 10–14 S 8–12 S 6–10 S 5–8 S 5–8 S

3 8–12 S 8–12 S 6–10 S 5–8 S 4–6 K 4–6 K

4 6–10 S 6–10 S 5–8 S 4–6 K 4–6 K 4–6 K

5 6–10 S 5–8 S 4–6 K 4–6 K 4–6 K 3–4 K

6 5–8 S 5–8 S 4–6 K 4–6 K 3–4 K 3–4 K

8 5–8 S 4–6 K 4–6 K 3–4 K 3–4 K 3–4 K 10 4–6 K 4–6 K 4–6 K 3–4 K 3–4 K 2–3 K 12 4–6 K 4–6 K 3–4 K 3–4 K 2–3 K 2–3 K 15 4–6 K 3–4 K 3–4 K 2–3 K 2–3 K 2–3 K 20 3–4 K 3–4 K 2–3 K 2–3 K 2–3 K 2–3 K 30 3–4 K 2–3 K 2–3 K 2–3 K 1,4–2 K 1,4–2 K 50 2–3 K 2–3 K 2–3 K 1,4–2 K 1,4–2 K 1,4–2 K 75 - 2–3 K 1,4–2 K 1,4–2 K 1,4–2 K 0,75–1,25 K

100 - - 1,4–2 K 0,75–1,25 K 0,75–1,25 K 0,75–1,25 K 150 - - - 0,75–1,25 K 0,75–1,25 K 0,75–1,25 K 200 - - - 0,75–1,25 K 0,75–1,25 K 0,75–1,25 K

SOLID MATERIAL (D = mm)

Constant tooth system Variable tooth system

length of the cut D tooth system (ZpZ) length of the cut D tooth system (ZpZ)

to 3 mm 32 to 30 mm 10 –14

to 6 mm 24 20–50 mm 8–12 to 10 mm 18 25–60 mm 6–10 to 15 mm 14 35–80 mm 5–8

15–30 mm 10 50–100 mm 4–6 30–50 mm 8 70–120 mm 4–5 50–80 mm 6 80–150 mm 3–4

80–120 mm 4 120–350 mm 2–3 120–200 mm 3 250–600 mm 1,4–2 200–400 mm 2 500–3000 mm 0,75–1,25 300–800 mm 1,25

700–3000 mm 0,75

Note: Run regrinding saw bands too.

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3. Machine control

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3.1. Main switch



Main switch

It is on the vice side of the distributing box. It is not depicted on the diagram.

3.2. Control elements

3.2.1. Ergonomic 320.250 DGS without frequency converter

Switch of the cutting speed

Select the cutting speed during cutting (40 or 80 m. min-1).

TOTAL STOP button

In case of emergency, the machine is stated to the order!

ATTENTION! By pressing button TOTAL STOP is not stopped saw frame sinking!

START

Start of the saw band drive.

34 5

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STOP

Stop of the saw band drive.

Governing valve

Adjust the speed of the arm sinking to the cut by governing valve. Notice: If you keep closing the throttle valve too tightly, the valve seat may wear off which

causes its leakage. Therefore, close the valve always gently.

3.2.2. Ergonomic 320.250 DGS with frequency converter

Switch of the cutting speed Select the cutting speed during cutting (20–120 m. min-1).

TOTAL STOP button

In case of emergency, the machine is stated to the order!

ATTENTION! By pressing button TOTAL STOP is not stopped saw frame sinking!

START

Start of the saw band drive.

STOP

Stop of the saw band drive.

Governing valve

Adjust the speed of the arm sinking to the cut by governing valve. Notice: If you keep closing the throttle valve too tightly, the valve seat may wear off which

causes its leakage. Therefore, close the valve always gently.

4 5

120

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3.3. Machine control

3.3.1. Cutting

1. Open the vice of the band saw.

2. Set the length stop to the desired length of the material.

3. Set the desired cutting angle.

4. Insert the material and pull it to the length stop.

upnout spannen tighten

povolit lösen loosen

5. Pull vice jaws about 5 mm from the material by hand wheel.

6. Tighten the material by the clamping lever.

7. Set the saw band speed.

8. Start saw band drive by button START.

9. Set the speed of the saw frame sinking.

10. Close the governing valve of the frame sinking and lift the saw frame to the top

position after cutting

11. Remove the cut. Now you can repeat whole progress.

3.3.2. Setting of the material length

Release the securing screw, move the length stop on the desired length of the material and fasten the securing screw..

Note: Saw band drive is possible to stop by button STOP or by button TOTAL STOP in emergency causes during cutting. ATTENTION! Saw frame sinking is possible to stop by governing valve closing! By pressing button TOTAL STOP is not stopped saw frame sinking!

Note: The length stop makes bounce listel of the material, so that the saw band will be not compressed in the cut. Turn the lever to the arrow direction..

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3.3.3. Cutting speed adjustment

Picture Description

Ergonomic 320.250 DGS without freq. converter

• speed 40 m.min-1 – turn speed switch into pos. no. 1

• speed 80 m.min-1 – turn speed switch into pos. no. 2

Ergonomic 320.250 DGS with freq. Converter

• Change bansaw speed by frequency converter in range

20–120 m.min-1.

3.3.4. Angular cut setting

The cut angle can be varied from -45° to 60°. The angles -45°, 0°, +45° and 60° is set by means of the fixed stop.

Picture Description

povolit lösen loosen

utáhnout festziehen tighten

1. Loosen the saw arm and release-securing

lever of the console.

2. Set the desired angle of the cut. If you want

set the cut angle bigger then 45°, pull out the stop pin.

3. Turn the saw frame to the desired angle

according to the scale on the turning console and tighten the securing lever of the console.

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angle < 0°

angle ≥ 0°

4. Shift the vice according to setting angle of

the cutting. Shift the vice to the right for angle of the cut, which is less than 0°, shift the vice to the left for angle of the cut 0° or for angle of the cut, which is bigger than 0°

3.4. Material insertion

• Never walk under a suspended load!

• Never climb onto the gravity-roller conveyor!

• Do not hold the material for clamping material to the vice! The vice can cause

injury!

3.4.1. Handling agent selection

• Use the strong handling agents to lift and transfer the material!

• Handle with the material only with the lift truck or use the suspension strands and

the crane!

• Do not use the lift truck or crane in case that you do not have the license to handle

with it!

3.4.2. Insertion

Insert material to the vice and ensure that the material cannot move in the vice or fall from the vice after the clamping. If you cut long pieces of the material (for example rod, tube), you must use the roller conveyors for material shifting to the band saw. Contact Bomar for more information about roller conveyors

Make sure the conveyor is long enough and the material cannot tip off the conveyor.

Be especially careful with round materials that it always stays on two vertical rollers and that it cannot fall off the conveyor!

3.4.3. Bundle material cutting

If you want to cut the material in the bundle, there are suggestions for the positioning of bundles

Round material bundle: Take care especially with round material that the bars are put according to the picture. If the bars are put differently, you may have problems with movement.

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Always weld the material at the rear end of the bundle to secure it from moving.

Before welding always, switch the machine off at the main switch! The magnetic fields, which often occur during welding, may damage the controls!

Square material bundle:

Attention:

Not all material shapes are suitable for bundle cuts. Keep the recommendation of your supplier of the saw bands for material insertion to the bundle.

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4.1. Saw band dismantling

1. Lift the saw frame to the top position. Stop the saw frame in top position by

control valve.

2. Dismantle yellow protective cover of the saw band. The cover is clamped with two

screws.

3. Dismantle back covering sheet metal of the saw frame. The covering sheet metal is

clamped with two screws with plastic head.

4. Release brush holder and turn it. The brush must not defend saw band

dismantling.

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5. Turn by stretching star to the left side, release saw band stretching and pull saw

band from blade wheels.

6. Pull up the saw band from the guiding cubes.

4.2. Saw band installation

1. Prior to installation, clean all track wheels, guide cubes and inner side of the arm

thoroughly of all traces of chips and dirt. Keep in mind the teeth direction when installing the saw band.

2. Insert new saw band in the guide cubes. Make sure the saw band runs between

both guide rollers and it is pushed all the way to the top.

3. Put the saw band on both guide wheels. Make sure that the saw band ridge fit

tightly to the wheel rim. Then push the saw band as far back as possible.

4. By turning the stretching star to the right, you will stretch the saw band slightly.

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5. Put the brush into the function position and screw up the holder.

6. Install the rear protective cover of the frame.

7. Install the yellow protective cover of the band. The arrow on the cover must match

the direction of the arrow on the band. If it does not, you must turn the band round.

4.3. Saw band stretching and inspection

Right saw band stretching is one of the most important criteria’s, which influents accuracy and saw band service life. Stretch the saw bands according to the selected saw band and the band saw. Keep the recommendation of your manufacturer.

4.3.1. Saw band stretching

1. The saw band must not fall from the wheels after setting.

2. Install the Tenzomat on the saw band and secure it with screws.

3. Stretch the saw band until it is stretched to the recommended value.

4.3.2. Saw band inspection

Check the saw band in the guiding cubes and on the wheels

1. Check, if the saw band is right in the guiding cubes..

2. Switch on the saw band drive and then after 10 seconds switch off saw band drive.

If the saw band drive is not possible to switch on, set the limit switch of the saw band stretching.

3. Switch off the main switch.

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4. Open cover(s) of the wheels and check position of the saw band on the both

wheels..

• If the distance between backside of the saw band and the offset wheel is 1 mm,

setting is right..

• If the distance is bigger than 1 mm, or the saw band is on the offset of the wheel,

set the saw band.

5. Close cover of the saw band.

4.4. Adjustment

4.4.1. Saw band petting

The saw band run is set with screw in the stretching cube on the saw frame. Optimal distance has been determined at 1mm

• Turn by screw to the right, the saw band approximates to the stretching

wheel rim

• Turn by screw to the left, the saw band departs from the stretching wheel rim

Check saw band run again after setting

4.4.2. Hard metal guides adjustment

Hard metal guides adjustment is one of the most important criterions which influences cutting accuracy and saw band life. Therefore it is essential to regularly check that hard metal guides adjustment is correct

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1. Tighten the stop screw on the rear side of guide cube so that the band cannot to

move

2. Release the stop screw and at the same time grip the saw band by hand and

check if the hard metal guide does not put up to much resistance against the movement of the band. As soon as it is possible to move the band without resistance the hard metal guides are adjusted

Be sure that the hard metal guides do not put up to much resistance otherwise the lifetime of the saw band and drive decreases.

4.4.3. Guide cube adjustment

Cutting quality and saw band life is also dependent on guide cubes adjustment

Therefore this adjustment has to be checked periodically

1. Loosen both tightening screws of the guide cubes and push it carefully to the

band. Make sure the saw band is not bent; otherwise this cube will push on the band and damage it

2. Fasten both tightening screws again

4.4.4. Brush adjustment

The brush has essential influence on cutting performance, saw band lifetime and lifetime of wheels and hard metal guides and finally cut accuracy. Therefore the brush has to be checked during every shift.

1. Release the tightening screw of the brush so that it is possible to move with the

brush.

2. Get the brush closer to the saw band teeth. After the brush is set, its ends must

not reach the saw band teeth bottoms..

3. Tighten the screw again and turn on the band driver.

4. If the chip removing brush is correctly fastened the brush moves and turns

smoothly with the saw band.

Notice:

If the guide cube is correctly adjusted, upper cube edge and the ruler are parallel.

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4.4.5. Angular stops adjustments

There are two fixed stops with adjustable screw on the console. The angular stoppoints setting have to be periodically inspected to prevent inaccurate angular cuts

1. In order to check angular stop settings, turn the arm to the fixed stop and put the

protractor on the saw band and vice jaw

2. If the angles are not set correctly, release the nut on the stop screw. You can set

smaller angles by tightening the screw. You can set larger angles by loosening the screw

3. Fasten the nut again and check the angle setting with the protractor according to

procedure above

angle 0° angle 45° Angle 60°

4.4.6. Adjusting the limit switch of the saw band stretching

After the saw band is replaced, the limit switch setting must be checked out. If the limit switch is not set correctly, the band is stretch too much or it is to loose

1. Stretch the band by means of TENZOMAT–on the optimal value

2. Release the nut on the stop screw

3. Start the driving engine. Two scenarios may occur: a) If the engine is switched on, but it does not run, turn the screw to the left

until the engine starts to run

b) If the engine runs turn the screw to the right until it stops to run, then turn

the screw shortly to the left until the engine starts to run again

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4. Secure the stop screw with nut and check the switch setting once more

ATTENTION!

If the band is stretched to the value according the TENZOMAT but the holder of thstop screw is not situated on the boundary of the red and green colour, it is necessary to stick the sticker in the correct place.

4.4.7. Saw frame lower position stop adjustment

The lower stop limits the lowest position of the saw frame. This stop point has to be checked at least once a month. If the lower stop point is wrongly adjusted, the cutting table can be deeply cut or the material will not be cut completely

1. Move the saw frame to the upper position

2. Release the nut of the adjusting screw and adjust the stop point by adjusting the

screw

3. Fasten the adjusting screw with the nut again

4. Set the limit switch of the lower arm position

4.4.8. Adjustment of the limit switch of saw frame lower stop point

If you have adjusted the lower stop point of the saw frame, the limit switch adjustment inspection is required

Check setting

Lower the arm to the lowest position. If the arm lays on the lower stop and the switch reacts, the setting is correct. In other case carry out the switch setting

Switch setting

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1. Release the nut of the stop screw and screw down the stop screw

2. Lower the arm to the lower stop and turn on the band driver

3. Screw out the stop screw until the band driver stops

4. Secure the screw with nut again and check the limit switch setting once more

4.5. Cooling agents and chips disposal

The quality of the cooling

agent will deteriorate due to:

If the solution is too weak: If the solution is too strong:

• use of contaminated water

• impurity

• outside oil contamination

(hydraulics, gears)

• high operating temperatures

• lack of air circulation

• wrong concentration

•

corrosion protection is

diminished

• lubrication decreases

• microbial attack is more likely

• the cooling ability is decreased

• foam behaviour increases

• emulsions stability deteriorates

• sticky residue develops

4.5.1. Coolant device inspection

The state of the cooling agent has significant influence on the cutting quality and on the operational life of the machine. Lifetime of the cooling liquid is 1 year, after this time we recommend change the cooling liquid. This time is dependent on the degree of pollution cooling liquid (especially with oils) and on the other factors.

Check level of the cooling liquid and function of the pump periodically!

Check the state of the cooling agent according to the following table:

Testing Interval Method Condition Precaution

Liquid level

daily visually too low

after concentration check, refill with water or emulsion

Concentration

daily

refractometer densimeter

too high too low

refill water refill base emulsion

Smell

daily by sense of smell unpleasant smell

good ventilation, add biocides or renew coolant

Contamination

daily by sense of smell

visible oil leaks, sludge fungi

surface cleaning, fix leaks, add biocides or fungicides, or coolant renewal after added system cleanser*

Corrosionprotection

when necessary

visually chip test Herbert-test

insufficient corrosion protection

test stability, if necessary – increase concentration or pH value

Stability

when necessary

refractometer oiling

add concentrate, enquiries to supplier

Foam reaction

when necessary

shaking test

too much foam, foam disperses too slowly

avoid aeration, increase water hardness, ix with defoamer

* according to manufacturers’ instructions

4.5.2. Cooling liquid preparation¨

Prepare the mix of the water and cooling liquid. Conform the notes of the manufacturer and keep manufacturer-approved concentration

All instructions are stated on the tank of the cooling liquid or in documents of the cooling liquid. For cooling liquid using and liquidation reads date of cooling liquid manufacturer, which it is necessary to keep

Fill the mix of water and cooling liquid to the tank of the cooling system. The capacity of the tank for the cooling liquid is stated in chapter „2.1

When filling tank with the cooling liquid take care that the liquid will not drip out of the tank and the tank will not overflow

Note:

If the state of the cooling liquid is not satisfactory, the cooling liquid must be changed.

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Keep manufacturer specified recommendations for adding the anticorrosive agents, the antifreeze or other agents! For mixture of two different mixes can produce toxic and aggressive mixes, which can peril your health or damage cooling system of the machine

Note: If the machine is equipped with Microniser (see. Special accessory), fill the tank of the Microniser by specified cooling liquid. Microniser is ready for the operation

The quality of the cooling agent will deteriorate due to:

• use of contaminated water

• impurity

• outside oil contamination (hydraulics, gears)

• high operating temperatures

• lack of air circulation

• wrong concentration

If the solution is too weak:

• corrosion protection is diminisched

• ubrication decreases

• microbial attack is more likely

If the solution is too strong:

• the cooling ability is decreased

• foam behaviour increases

• emulsions stability deteriorates

• sticky residue develops

4.5.3. Chips disposal

Chips resulting from cutting operations must be disposed of in accordance with the relevant regulations.

• Let the chips drip excess fluid!.

• Fill a watertight container with the chips! Be careful that the container does not

leak, because even after a long dripping time, they still contain coolant residue.

• Place the container into the care of a disposal company equipped for the disposal of

chips contaminated with cooling liquid. In case the machine is equipped with micro-

spray installation, the chips must also be handed over to a disposal company.

4.6. Greases and oils

4.6.1. Gearbox oils

In gearboxes, oil is used for the whole lifetime of the gearbox. We recommend replacing of the filling oil in case of repair.

Use oils with specification DIN 51517 in the gearboxes. Select the viscosity grade ISO VG according to the original oil fill.

Attention:

When replacing, use oils recommended by BOMAR or oils, which has comparable parameters from the other manufacturers. Do not forget, that mineral and synthetic oils must not be mixed!

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Recommended oils and quantity according to the type of the band saw

Band saw Gearbox oil Capacity

Ergonomic 320.250 DGS

Paramo PP7

2 l

Swarf conveyer

Shell Tivela S 320

0,075 l

Comparative table of the gearbox oils

Manufacturer

Viscosity grade

ISO VG 100 ISO VG 220 ISO VG 320

BP Energol GR-XP 100 Energol GR-XP 220 Energol GR-XP 320

Castrol

Alpha SP 100

Alpha MW 100

Alpha SP 220

Alpha MW 220

Elf Reductelf SP 100

Reductelf SP 220

Reductelf Synthese 220

Reductelf SP 320

Esso Spartan EP 100 Spartan EP 220 Spartan EP 320

Mobil Mobilgear 627

Mobilgear SHC 220

Mobilgear 630

Mobilgear 632

ÖMV PG 220

Paramo PP 7 Paramo CLP 220 Paramo CLP 320

Shell Shell Omala 100

Shell Omala 220

Shell Tivela S 220

Shell Omala 320

Shell Tivela S 320

Total Carter EP 100 Carter EP 220 Carter EP 320

4.6.2. Lubricant greases

We recommend using lithium based saponified grease, class NGLI-2 for lubrication. Different greases are mixable, if their oil bases and consistence type are identical.

Comparative table of the lubricant greases:

Manufacturer Type of the lubricant grease

BP Energrease LS - EP

DEA Paragon EP1

Esso

FETT EGL 3144

Beacon EP 1

Beacon EP 2

FINA FINA LICAL M12

Klüber

Microlube GB0

Staburags NBU8EP

Isoflex Spezial

Optimol Optimol Longtime PD 0, PD1, PD2

Shell Aseol AG ASEOL Litea EP 806-077

Texaco Multifak EP1

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4.6.3. Lubrication

Na stroji se vyskytuje několik uložení, která je nutno pravidelně promazávat, aby byla zajištěna správná funkce stroje.

Lubrication place Description

The upper pivot of the lifting cylinder – drop the oil once a week.

4.6.4. Hydraulic oils

Replace the hydraulic oil once in 2 years, because the oil can deteriorate its properties and cause problems the hydraulic equipment. If the hydraulic system is equipped with filter (2SF 56/48-0,063), replace the filter too.

Use oils with specification DIN 51524-HLP, ISO 6743-4 and viscosity grade ISO VG 46 in hydraulic aggregates.

Comparative table of the hydraulic oils:

Manufacturer Type Manufacturer Type

Agip Oso 46 Ina Hidraol 46 HD Aral Vitam GF 46 Klüber Lamora HLP 46 Avia Avilub RSL 46 Hungary Hidrokomol P 46 Benzina OH-HM 46 Mobil Mobil DTE 25 BP Energol HLP 46 ÖMV HLP 46 Bulgaria MX-M/46 Poland Hydrol 30 Castrol Hyspin AWS 46 Rumania H 46 EP Čepro Mogul HM 46 Russia IGP 30 DEA Astron HLP 46 Shell Tellus Oil 46 Elf Elfolna 46 Sun Sunvis 846 WR Esso Nuto H 46 Texaco Rando HD B 46 Fam HD 5040 Valvoline Ultramax AW 46 Fina Hydran 46

Note:

When replacing, use oils recommended by BOMAR or oils, which has comparable parameters from the other manufacturers. Do not forget, that mineral and synthetic oils may not be mixed!

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4.6.5. Hydraulic oil level check

Note: This chapter is only for the band saws, which has hydraulic equipment

Recommended type of the hydraulic oil is placed in chapter Hydraulic oils

Pull up the gauge and check the state of the oil. The oil level must be situated in waterglas.

Fill the hydraulic oil, if it is necessary. Use always the filter (25 μm or better) when you fill the oil. You avoid impurities penetration to the hydraulic system and troubles in hydraulic system

4.6.6. Adjustment of a throttle valve

1. Switch off the machine by its main switch. Let the sawing head down at the bottom. Close the throttle valve gentl

2. The worm screw (pos. A) must be next to the stop (pos. B), when the valve is closed

A B

3. Otherwise, you must loosen the worm screw, lift the plastic knob and close the throttle valve to the maximum. Next loosen the worm screw and take off the plastic knob. Put it back so that the worm screw must be next to the stop while the valve is closed. Then tighten the worm screw again

4. Turn the machine on and test the down-feed control

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4.7. Machine cleaning

Clean the machine from the cooling liquid and impurities after every shift stopping. Conserve the guiding surfaces, mainly.

• Clamping jaws guiding of the main and feeding vice.

• The guiding of the feeder.

• Loading surface of the main, feeding vice, and area under them.

• Threaded bar of the main and feeding vice.

4.8. Worn pieces replacement

4.8.1. Hard metal guides replacement

If the hard metal guides cannot be adjusted, they have to be replaced.

1. Remove the hosepipe leading to the cooling agent and dismantle saw band and

saw band guiding cube.

2. Fasten the guiding cube to the vice and screw out the screws of both the hard

metal desks.

3. Screw out the adjusting screw of the adjustable guiding desk as far from the guide

cube so that it is not possible to see it from the inner side.

4. Now insert new hard metal guides and fasten them tightly and fasten the guide

cube to the gib.

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5. Install the saw band and adjust guide cube and hard metal guides.

4.8.2. Saw band guiding rollers replacement

If the saw band is not sufficiently guided by guiding rollers and/or if the rollers are obviously worn, the rollers should be replaced.

Attention! Guiding rollers must be replaced together on both guide cubes!

1. Remove the hosepipe leading to the cooling agent and dismantle saw band and saw band guide cube.

2. Grip the guide cube in the vice and screw out both fastening screws of the eccentrics.

Attention!

Vice must has aluminum jaws or should be placed in a vice aluminum produc, that avoid damage to the pin during clamping.

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3. Pull both guide rollers from their eccentrics.

4. Put new guide rollers on the eccentrics and screw the eccentrics to the guide

cube.

5. Now insert a test piece of saw band (cca 15 - 20 cm) into the guide cube. Adjust

both eccentrics so that the band runs in the middle of milled groove. This groove is located between both eccentrics. Guide rollers may not press too much on the band, but they must spin freely.

6. Install the cube on the gib. Install the saw band and adjust guiding cubes.

4.8.3. Round brush replacement

If the chip removing brush is so worn, that it does not fulfil its function, the brush must be replaced.

1. Release the nut of the brush, exchange old brush to new brush and screw on the

nut of the brush.

2. Set the brush to the saw band.

Attention!

Vice must has aluminum jaws or should be placed in a vice aluminum produc, that avoid damage to the pin during clamping.

Optimal distance between band and roller is 0,05mm.

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4.8.4. Stretching wheel replacement

1. Dismantle the saw band.

2. Screw off the screw of the stretching wheel and pull off the washer.

3. Screw on the auxiliary screw to the shaft of the stretching wheel.

4. Put on the three-leg puller on the stretching wheel and pull off it from the shaft.

5. If the lower bearing stays on the shaft, pull of it from the shaft with two-leg puller. Check both bearings; eventually replace them for a new.

6. Insert the retaining ring to the hole in the new stretching wheel.

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7. Insert the bearing to the hole in the wheel and push it to the retaining ring.

8. Clean the shaft and oil it. Install the new stretching wheel on the shaft.

9. Install the distance ring on the shaft and push it to the lower bearing.

10. Install second bearing on the shaft and push it to the distance ring.

11. Install the washer and screw on the stretching wheel.

12. Install the saw band. Wheel replacement is ready.

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4.8.5. Driving wheel replacement

1. Dismantle the saw band.

2. Screw of the fastening screw of the driving wheel and pull off the washer.

3. Screw on the auxiliary screw to the driving shaft.

4. Install the three-leg puller on the driving wheel and pull off it from the shaft.

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5. Check, if the feather and the driving shaft are not damaged. Contact your supplier

for parts replacement.

6. If the shaft and the feather are in good order, clean them, oil them and install them

on the driving shaft.

7. Install the washer and screw on the driving wheel.

8. Install the saw band.

4.8.6. Cooling pump replacement

Only a qualified worker can carry out the connection! High-voltage shock may have fatal results.

1. Pull out the cooling agent tank from the machine base as far as possible.

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2. Remove the hosepipe leading the cooling agent from the connection on the pump. Unscrew four screws on the cooling pump flange and pull out the pump from the metal sheet holder.

3. Remove the cover of the pump terminal switchboard. Disconnect 4 terminal connectors of the input cables. Cables are identified according to the red clamps.

4. Loosen the bushing and pull the cable out from the pump.

5. Dismantle new pump switchboard cover. Push the cable through the bushing and fasten it.

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Závady

Troubleshooting

5. Závady /

Troubleshooting

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Závad

Troubleshooting

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Závady

Troubleshooting

5.1. Mechanical problems

Problem Possible causes Repair

1. Slanting cut

- Wrongly adjusted hard metal guides. Set according to the chapter „Servicing and adjustment“

- Worn hard metal guides. Replace to the chapter „Worn pieces replacement“

- Wrongly adjusted cubes of the saw

band guiding.

Set according to the chapter „Servicing and adjustment“

- Worn bearings of the saw band guiding. Replace according to the chapter „Worn pieces replacement“

- Wrongly adjusted swarf brush. Set according to the chapter „Servicing and adjustment“

- Worn swarf brush. Replace according to the chapter „Worn pieces replacement“

- Insufficient saw band stretching. Rise the saw band stretching and set the limit switch.

- Wrongly chosen tooth system of the

saw band.

Replace the saw band and keep the instructions of manufacturer on new saw band choice.

- Worn saw band. Replace the saw band.

- Wrongly balanced roller conveyor. Set the roller conveyor.

- Dirty feeding board. Cleanse the feeding board from debris, chip and residue material.

- Guiding arm and guiding cube are

loosened.

Clamp the guiding arm.

- Guiding arm and cube are too far from

the material.

Set the guiding cube to the material.

- Too fast cutting rate. Lower the material feeding speed.

- Unexpected oscillation in material

quality.

Set the cut and feeding speed to the relevant material.

2. The cut is not cut

upon desired angle

- Securing lever is loosened. Check the securing lever efficiency and carry out its adjustment according to chapter „Servicing and adjustment“.

- Set angle does not match the cut angle. Check the angle adjustment with a protractor and possibly set it according to chapter „Servicing and adjustment“.

- Insufficient saw band stretching. Stretch the saw band and set the limit switch according to chapter „Servicing and adjustment“.

- Guiding arm and guiding cube are

loosened.

Fasten the guiding arm and the cube.

- Dirt between material and clamping

jaw.

Cleanse the material and mating jaw.

3. Short lifetime of the

saw band

- Insufficient saw band stretching. Raise the tightening of the saw band set the scanner of saw band tightening according to chapter „Servicing and adjustment“.

- Worn swarf brush. Check the swarf brush condition and replace it in case of excessive use as described in chapter „Worn pieces replacement“

- Wrongly adjusted swarf brush. Check swarf brush adjustment, set it according to chapter „Servicing and adjustment“

- Over stretched saw band Lower stretching of the saw band and set the limit switch of the saw band stretching according to chapter „Servicing and adjustment“

- Wrongly adjusted hard metal guides. Check the adjustment of the hard metal guides and carry out adjustment as described in chapter „Servicing and adjustment“

- Worn hard metal guides of the saw

band.

Check the condition of the hard metal guide and if it is too worn, replace hard metal guides according to chapter „Worn pieces replacement“

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Závad

Troubleshooting

Problem Possible causes Repair

- Worn saw band guide bearings. Check guiding bearings and if you notice some sort of excessive damage, replace them according to chapter„Worn pieces replacement“

- Wrongly adjusted guiding cubes of the

saw band.

Set guiding cube according to chapter „Servicing and adjustment“

- Wrongly adjusted down feed and saw

band speed.

Adjust the feeding and speed of a saw band according to values published by saw band manufacturer.

- Different material quality. Adjust feeding and speed of a saw band according to desired material (try cut-test).

- Low-class saw band Replace the saw band (contact your local accessory supplier for more information)

- Wrongly chosen saw band tooth

system.

Replace the saw band and keep instructions of the manufacturer on the choice.

- Wrongly adjusted tracking. Check the space between top of a saw band and driving wheel. Perhaps adjust the tracking as described in chapter „Servicing and adjustment“

4. Insufficient cut

output.

- Worn saw band. Replace the saw band and keep instructions of the manufacturer on the choice.

- Wrong saw band tooth system. Replace the saw band and keep instructions of the manufacturer on the choice.

- Wrongly set down feed and speed of a

saw band.

Set feed and speed of a saw band according to values published by saw band manufacturer.

5. The cut is not finished.

- Wrongly adjusted lower stop point of

the saw frame.

Check lower limit switch and screw.

- Stop point surface is messed-up. Cleanse stop point surface of the limit switch from debris and residue material.

6. By choke is not

possible turn

- Metal clamps between valve and panel. Clamps must be removed and put on the shaft ORing about 10x2 mm.

- Metal clams are in body of valve. Valve must be cleared or changed.

7. Saw band drive

cannot be started.

- Pressure switch is adjusted wrong. Set the pressure switch according to chapter „Servicing and adjustment“

- Pressure switch is defective. Replace defective parts of the pressure switch.

8. The saw bands are

cracked.

- In stretching wheel is wrong adjusting

geometry.

Adjust distance band from recess wheel c.2 mm according to operating instructions.

- Hard metal plates of circuit saw band

are not adjusting.

Hard metal plates of circuit saw band must be adjusting according to operating instructions.

- Guiding cubes are not adjusting

(bearings + hard metal circuit)

Guiding cubes must be adjusting (bearings + hard metal circuit) according to operating instructions.

- Bearings of guiding cubes are used

(rolling elements are damaged or outside ring of bearing has conical form).

Bearings of guiding cubes must be replaced. Bearings must be adjusting according to operating instructions.

9. Damage tooth system

of the saw band

- In gripping the lifting cylinder is

backlash.

- Squeezed pin upper or downer holder

of the lifting cylinder.

Exchange complete upper or downer holder of lifting cylinder.

10. The saw is cut

downing.

- Geometry of hardmetal guiding cubes is

wrong adjusted.

Hardmetal guiding cubes must be adjusted.

- Bearings of guiding cubes are used. Bearings of guiding cubes must be replaced.

11. Cleansing of the saw

band is not functional.

- Elastic wheel of the brush drive is worn-

down.

Elastic wheel of the brush must be changed.

- Knurling of the driving wheel is worndown.

Driving wheel must be changed.

- The shaft of the brush drive is rusted. The shaft of the brush must be cleaned and oiled.

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Závady

Troubleshooting

Problem Possible causes Repair

- The brush position and the brush cover is adjusted wrong – with the brush cannot be turned.

The brush cover must be posed, in order to the brush can be turned.

12. The saw arm

periodically rise and fall during the cut; this cause short lifetime of the saw band.

- Backslash in driving wheel lodgement on the shaft.

Change the driving shaft for a long one, new bearings, distance ring, new driving wheel, spring, two covers on the forehead of the shaft + screws.

- Worn channel for spring.

5.2. Electric problems

Problem Possible causes Repair

1. Machine is not

possible start.

In socket is not voltage Line voltage must be checked.

Transfer relay is closed (thermal protector)

Each FA relay must be checked.

Limit switch of saw band stretching, cover of frame or cover of saw band is not started.

Check of saw band stretching and covers closing.

2. When cut is finished,

the frame is not raising.

- Bottom limit switch is adjusted wrong. Bottom limit switch must be adjusted according

to chapter ADJUSTING.

- In hydraulic (pneumatic) ring is error. HYTOS (BOSCH) is not acting to frame uplift.

Function of magnetic valve must be checked, valve must be closed, voltage of clamps and inductor must be checked.

3. Electric motor and

pump are without voltage. Between contactor and thermal protector is not voltage.

- Wrong contactor. Replace contactor of engine.

4. The indicator of speed

saw band is not functional.

- Sensor of speed is not adjusted. Sensor of speed must be adjusted.

- Defective display The display must be changed.

- Wrong sensor – diode of indicator speed is not light.

Sensor must be changed and adjusted.

5. Protector is switched

off from engine hydraulic aggregate MA3 sometimes.

- Into hydraulic system is high working pressure.

Service engineer must reduce the pressure in hydraulic system.

6. The hydraulic

aggregate cannot be started

Auxiliary contact on thermo-relay FA1 is

defective.

Replace the defective contact on motor starter FA1.

7. Hydraulic aggregate is

switched on but the saw arm or the main vice is not functional

- Wrong connection of electrical supply. The electrical phases are connected conversely.

The phases must be switched. Only service engineer can do this.

8. Cooling is not active

Lack of cooling agent. Fill the tank with cooling agent.

- Thermal relay is defective Change the thermal relay

- Input hosepipe is broken or obstructed. Check the cooling circuit and perhaps cleanse

cooling system.

- Cooling pump protection is defective Check the protection of cooling pump if need

change it.

- Cooling pump is defective. Replace the cooling pump.

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

6. Schémata /

Schemas / Schematics

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

6.1. Elektrická schémata / Elektroschemas / Wiring diagrams –

bez frekv. měniče / ohne Frequenzumrichter / without frequency convertor – 3×400 V/50 Hz, TN-C-S

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

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Schemas

Schematics

Objednací číslo Název položky

Ozn. ks

Bestell - Nr. Bezeichnung

Signatur Menge

Reference No. Item Sign. Pcs.

91.001.007

Elektromotor / Elektromotor / Electromotor

TM902/4 B5 M1 1

91.020.006

Čerpadlo chlazení / Kühlmittelpumpe / Coolant pump

3COA2-22H M2 1

91.040.001 Stykač / Schaltschütz / Contactor 9A 230V KM 1

91.050.003

Relé tepelné / Electro thermal relay / Thermorelais

0.26-0.43A FA2 1

91.050.009

Relé tepelné / Electro thermal relay / Thermorelais

3.0-4.7A FA1 1

91.060.012

Hlavice TOTAL STOP / NOT-AUS Taste / Total stop jugulum

ZB5AS844 SB1 1

91.061.006

Kontakt rozp.+adapt. / Schaltkontakt / Expand.+adapt. contact

ZB5AZ102 SB1 1

91.060.015 Hlavice rudá / Kopf – rot / Red jugulum ZB5AA4 SB2 1

91.061.006

Kontakt rozp.+adapt. / Schaltkontakt / Expand.+adapt. contact

ZB5AZ102 SB2 1

91.060.014

Hlavice zelená / Kopf – grün / Green jugulum

ZB5AA3 SB3 1

91.061.007

Kontakt spín.+adapt. / Schaltkontakt / Switch.+adapt. contact

ZB5AZ101 SB3 1

91.170.003 Spínač vačkový / Schalter / Cam switch 194L-E16-1753 QS1 1

91.180.001

Deska spínače černá / Schalterplatte – schwarz / Black board of the switch

194L-HE4E-175 QS1 1

91.171.006 Spínač vačkový / Schalter / Cam switch S10-60129 QS2 1

91.173.012

Spínač konc.-zámek / Endschalter / Limit switch-lock

QKS8 SQ3 1

91.173.007

Spínač koncový / Endschalter / Limit switch

Pizzato SQ1,2 2

91.230.001 Pojistka / Sicherung / Fuse 2A FU1 1

91.190.004 Krabice elektro / Buchse / Box 1

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Schémata

Schemas

Schematics

6.2. Elektrické schema /

Elektroschema / Wiring diagrams –

Erg. 320.250 G-F/DG-F/DGS-F, 3×400 V TN-C-S

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

Schémata

Schemas

Schematics

6.3. Elektrické schema /

Elektroschema / Wiring diagrams –

Erg. 320.250 G-F/DG-F/DGS-F, 3×400V TN-C

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

6.4. Elektrické schema /

Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F, 3×230 V

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

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Schémata

Schemas

Schematics

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Schemas

Schematics

6.5. Hydraulické schéma

Hydraulisches Schéma Hydraulic diagram

Poz. Název položky ks

Pos. Bezeichnung Menge Pos. Item

Pcs.

1 251.056

Hydraulický válec / Hydraulischer Zylinder / Hydraulic cylinder

2 92.152.002

Regulační ventil / Regelventil / Control valve HYTOS



7. Výkresy sestav pro

objednání náhradních dílů / Zeichnungen für Bestellung der Ersatzteile / Drawing assemblies for spare parts order

• Při objednávání náhradních dílů vždy uvádějte: typ stroje (např. practix Ergonomic

320.250 DGS) , výrobní číslo (např. 125) a rok výroby (např. 1999).

• In die Bestellung der Ersatzteile führen Sie immer an: Maschinentyp (z. B.

Ergonomic 320.250 DGS), Serien Nr. (z. B. 125) und Baujahr (z. B. 1999).

• For spare parts order, you must always to allege: type of machine (for example

Ergonomic 320.250 DGS), serial number (for example 125, see cover page) and year of construction (for example 1999).

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

7.1. Ergonomic 320.250 DGS



7.2. Kusovník / Stückliste / Piece list –

Ergonomic 320.250 DGS

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

7.3. Ergonomic 320.250 DGS



7.4. Kusovník / Stückliste / Piece list –

Ergonomic 320.250 DGS

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

7.5. Rameno / Sägerahmen / Saw arm

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7.6. Kusovník / Stückliste / Piece list –

Rameno / Sägerahmen / Saw arm

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Manual version: 1.02 / Mar. 2010 Manual rev.: 1

7.7. Rameno / Sägerahmen / Saw arm

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7.8. Kusovník / Stückliste / Piece list –

Rameno / Sägerahmen / Saw arm

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7.9. Napínání / Spannung / Tensioning

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7.10. Kusovník / Stückliste / Piece list –

Napínání / Spannung / Tensioning

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7.11. Vedení pásu / Sägebandführung / Belt guide

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7.12. Kusovník / Stückliste / Piece list –

Vedení pásu / Sägebandführung / Belt guide

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7.13. Vodící kostka / Führungsklotz / Guiding cube – 1

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7.14. Vodící kostka / Führungsklotz / Guiding cube – 2

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7.15. Konzola otočná/ Drehkonsole / Turnable consol

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7.16. Kusovník / Stückliste / Piece list –

Konzola otočná / Drehkonsole / Turnable consol

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100

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7.17. Svěrák / Schraubstock / Vice

Bomar Ergonomic 320.250 DGS, Ergonomic 320.250 DG, Ergonomic 320.250 DGH Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual