DoAll C-820 M Instruction & Parts Manual

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S
ERIAL NUMBER
27292
YEAR OF PRODUCTION
2007
STRUCTIO & PARTS MAUAL
INSTRUCTION &
INSTRUCTION &
INSTRUCTION &INSTRUCTION &
PARTS MANUAL
PARTS MANUAL
PARTS MANUALPARTS MANUAL
for
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Edition 2007-A
Band Saw Machine type
C-820 M
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Dear Customer,
first of all, thank you for choosing a DoAll product.
DoAll represents an important reference in the metal cutting business worldwide, and its production has always been recognized as synonymous of quality.
All machine components have been designed and manufactured to guarantee best possible performances. To keep this high standard, we kindly invite you to use only original DoAll spare parts.
DoAll band saw machines are CE marked and in the following pages the reader will find a CE declaration which follows the European Directive 89/392 requirements.
DoAll is sure to assure with this machine the state of the art solutions for the opera­tor safety, and to be part of the general improvement of labor conditions.
DoAll
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CE DECLARATIO ......................................................................................................................... 6
GEERAL IFORMATIO ........................................................................................................... 7
1. GEERAL IFORMATIO ....................................................................................................... 8
1.1. Goal of this manual. .................................................................................................................... 8
1.2. Regulations to refer. .................................................................................................................... 8
1.3. Manual description ...................................................................................................................... 8
2. MACHIE IDETIFICATIO DATA ....................................................................................... 9
2.1 Main constructive characteristics. .............................................................................................. 10
2.2. Blade speed ................................................................................................................................ 10
2.5. Vises ......................................................................................................................................... 10
3. HOW TO USE THE ISTRUCTIO MAUAL .................................................................... 11
3.1. Where to keep this manual ........................................................................................................ 11
3.2. Manual update ........................................................................................................................... 11
3.3. How to obtain more copies ........................................................................................................ 11
3.4. If the machine changes owner .................................................................................................. 12
3.5. Suggestions ................................................................................................................................ 12
4. LIABILITY LIMITS ................................................................................................................... 13
4.1 Inappropriate use of the machine ................................................................................................ 13
5. TYPE OF USE ALLOWED ........................................................................................................ 14
5.1. Machine addressee .................................................................................................................... 14
5.2. Operator ..................................................................................................................................... 14
5.3. Regulation.................................................................................................................................. 14
5.4 Typical use .................................................................................................................................. 14
5.5. Limits using the saw .................................................................................................................. 15
5.6. Workable materials .................................................................................................................... 15
5.7. Work area ................................................................................................................................. 15
5.8. Work place................................................................................................................................. 15
5.9. Command modes, stop, emergency stop and out of service. ................................................... 16
5.9.1 Command modes ............................................................................................................... 16
5.9.1.1. Stop ................................................................................................................................ 16
5.9.1.2. Emergency stop ............................................................................................................. 16
5.9.1.3. Out of service ................................................................................................................ 16
5.9.1.4. Safety precautions ......................................................................................................... 16
6. TECHICAL DESCRIPTIO ................................................................................................... 17
6.1. Machine structure ..................................................................................................................... 17
6.1.1. Base frame ....................................................................................................................... 17
6.1.4. Vices ................................................................................................................................. 17
6.2. Cutting bridge ............................................................................................................................ 17
6.2.1 Cutting bridge frame ......................................................................................................... 17
6.2.2 Guiding columns ............................................................................................................... 18
6.2.3 Columns connection .......................................................................................................... 18
6.2.4 Lifting cylinder .................................................................................................................. 18
6.2.5 Blade tension assembly ..................................................................................................... 18
6.2.6 Band drive assembly .......................................................................................................... 18
6.2.7 Band brush assembly ......................................................................................................... 18
6.2.8 Left and right band guides. ............................................................................................... 18
6.2.10 Wheels ........................................................................................................................... 18
6.2.11 Band drive motor ............................................................................................................ 18
6.3. Hydraulic power unit ................................................................................................................. 18
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6.3.1 Motor-pump assembly ....................................................................................................... 18
6.3.2 Oil reservoir ....................................................................................................................... 19
6.3.3 Solenoid valves ................................................................................................................. 19
6.4. Electrical system ....................................................................................................................... 19
6.4.1 Control console ................................................................................................................. 19
6.4.2 Control enclosure .............................................................................................................. 19
7. MACHIE PROTECTIOS ...................................................................................................... 20
8. HOW TO MOVE THE MACHIE ........................................................................................... 20
9. HOW TO ISTALL THE MACHIE ...................................................................................... 20
10. WHAT TO DO TO PREPARE THE MACHIE TO OPERATE ...................................... 21
11. SAFETY DEVICES ................................................................................................................... 22
11.1 Limit switches and signal devices ............................................................................................ 22
11.1.1. Limit switches ................................................................................................................ 22
11.1.2. Speed reducer ................................................................................................................. 22
11.1.3. Mechanical extra stroke .................................................................................................. 22
11.1.4. Signals ............................................................................................................................ 22
11.1.5. Led, indicators and signals to avoid danger situations .................................................. 22
11.1.6. Protection devices........................................................................................................... 22
11.2. Fix protections ......................................................................................................................... 22
11.3. Movable protections ................................................................................................................ 22
11.4. Safety features set-up ............................................................................................................... 22
12. MACHIE COTROLS ........................................................................................................... 23
12.1. How to operate the machine .................................................................................................... 23
12.1.1 Control panel with pushbuttons & selector switches ...................................................... 23
12.1.2 To start the machine ........................................................................................................ 24
12.1.3 To make a cut .................................................................................................................. 25
12.1.4 To stop the machine ........................................................................................................ 25
12.1.5 When an emergency occur .............................................................................................. 25
12.2. How to operate machines equipped with a saw1 control ........................................................ 25
12.2.1 Display ............................................................................................................................. 25
12.2.2 Standard controls ............................................................................................................. 25
12.2.3 Piece counter ................................................................................................................... 26
12.2.4 Coolant status .................................................................................................................. 26
12.2.5 Menu scroll ...................................................................................................................... 27
12.2.6 Machine emergency codes ............................................................................................... 27
12.3. Head feeding control ............................................................................................................... 27
13. CALIBRATIO AD TUE-UP ............................................................................................. 28
13.1. Calibration ............................................................................................................................... 28
13.2. Machine tuning-up ................................................................................................................... 28
13.3. Blade motor inverter ................................................................................................................ 28
13.3.1 Control panel ................................................................................................................... 28
13.3.2 Display ............................................................................................................................ 29
13.3.3 Help - function and language - selection ......................................................................... 29
13.3.4 Inverter status ................................................................................................................. 29
13.3.5 Warnings ......................................................................................................................... 30
13.3.6 Operating error messages ................................................................................................ 30
13.3.7 Hardware error messages ................................................................................................ 31
13.3.8 Programming structure .................................................................................................... 32
14. DISMATLIG OF THE MACHIE .................................................................................... 34
15. ORDIARY PROBLEMS......................................................................................................... 34
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15.1. Base ........................................................................................................................................ 34
15.2. Cutting bridge ......................................................................................................................... 34
15.2.1 Columns .......................................................................................................................... 34
15.2.2 Connection bar ................................................................................................................ 34
15.2.3 Lifting cylinder ................................................................................................................ 34
15.2.4 Blade tension assembly .................................................................................................. 35
15.2.5 Band drive assembly ........................................................................................................ 35
15.2.6 Guide arms ...................................................................................................................... 35
15.2.7 Band brush assembly ....................................................................................................... 35
15.2.8 Wheels ............................................................................................................................. 35
15.2.9 Servo-cutting device ........................................................................................................ 35
15.4 Hydraulic power unit ................................................................................................................ 35
15.5 Electric control panel ................................................................................................................ 35
16. MAITEACE ....................................................................................................................... 36
16.1 Lubrication .............................................................................................................................. 36
16.2. Problems .................................................................................................................................. 37
16.3. Blade replacement .................................................................................................................. 37
17. REMAIIG DAGERS ........................................................................................................ 38
18. PERSOEL TRAIIG ....................................................................................................... 38
19. MACHIE DISMATLE ........................................................................................................ 38
EXHIBIT A – PROOF OF TEST ................................................................................................... 39
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CE DECLARATIO
We declare that the product “Band saw machine type C-820 M”:
Serial number 27292 Year of production 2007
referred to in this declaration is in compliance with:
CEI EN 60204-1
UNI EN 12100-1
UNI EN 12100-2
and:
EEC Machine Directive 89/332 dated June 14, 1989 and amendments ;
EEC Low Voltage Directive 73/23 and amendments ;
EEC Directive 89/336 and amendments.
This product uses only tested and certified components, which meet the CE requirements, unless otherwise specified.
Vanzago, November 2007 IST Via Donatori di Sangue 15 20010 Vanzago – MI
Alessandro Rescaldani DoALL European factory manager
ECH SEGATRICI S.R.L
.
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GEERAL IFORMATIO
This machine has been designed and built adopting the state of the art technologies, and with respect of the European Laws for machine tools.
Notwithstanding what above, it is implicit that working underestimating or forgetting the dangers related to this kind of machine can generate, the operator could cause serious injuries to him/herself.
Therefore, the operator should carefully read the entire instruction manual, and respect strictly what prescribed in it.
This symbol indicates that the paragraph contains important information concerning safety and injuries preventions
In particular, please pay attention to the following suggestions:
Keep always your working area clean. Avoid to keep in your working area pieces of material, chips, cans, or other things which could reduce the possi-
bility of movement to the operator or even generate risks of injury.
Be always cautious using the machine, because, even if it is protected in every dangerous spot, it can be a dan-
gerous equipment, and thus it has to be use being particularly careful and aware.
Give immediately notice to your supervisor if the machine needs to be maintained or serviced, even if the prob-
lem is caused by inexperience. An incorrect use of the machine can be dangerous and can cause injuries.
Do not try to repair the problem if you are not sure of what caused it. ever service or maintain the machine when it is running. Always turn it off. ever leave the machine working without respecting the safety rules or removing the safety devices. Remove electrical power when the machine is not working. Always wear protective cloths, especially when replacing the blade. ever do anything imprudent. ever touch the unprotected part of the blade. ever cut any piece shorter than the shortest possible length. ever start cutting if the material is not firmly clamped by the vises. Move the material only if the cutting bridge is completely up.
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1. GEERAL IFORMATIO
1.1.
GOAL OF THIS MAUAL
This manual wants to explain instructions about how to operate safely, using texts, drawings, pic­tures and diagrams used by themselves or combined to instruct the operator to use the machine.
.
REGULATIOS TO REFER
1.2.
This manual was written to comply to the European Machine Directive UNI-EN 89/392 and following modifications, and based on UNI-EN 292/1 e 292/2 concerning a safe use of the machine.
1.3. M
AUAL DESCRIPTIO
This document contains information needed to:
install and make the machine work normal use of the saw how to maintain the machine how to service the machine how to dismantle the machine
.
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2. MACHIE IDETIFICATIO DATA
TAB 2.1
Identification data
Description
Band Saw machine
Type C-820 M Serial number 27292 Year 2007 Voltage and frequency 400 V 3ph+N+GND ±10% 50 Hz ±1% Approximate weight 6.000 Kg. Total power installed 15 Kw Total required current 45 Amp Control circuit 24Vdc Dangerous area Area around the machine (1.5meters) Working place Machine control panel Type of tool Band saw blade
TAB 2.2
Denomination or value
Technical Characteristics
Description C-820 M Round cutting capacity mm 820 Square cutting capacity mm 820x820 Band drive motor kW 11 Blade dimension mm 9700x67x1.6 Blade speed m/1’ 20-80 Hydraulic pump motor kW 4,0 Coolant pump motor kW 0.3 Hydraulic pump capacity l/1’ 27 Voltage of motors Vac 400 Control circuit voltage Vdc 24 Cutting kerf mm 2,5 Hydraulic reservoir l 100 Coolant reservoir l 100 Working height mm 670 Color DoALL blue Moving components color RAL Beige 1001
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2.1 M
AI COSTRUCTIVE CHARACTERISTICS
The machine uses:
Band speed readout
Metered feed control.
Band wheel drive with AC inverter and worm gear.
Hydraulic guide arm.
Carbide faced saw guides with large diameter lead in rollers on both guide arms.
Hardened, ground, anti-wear steel plates on all work clamping surfaces.
Ground, hardened and hard-chrome plated guide columns.
Power driven band cleaning brush.
Hydraulic band tension.
Recirculating, coolant system, pump 400/50/3, applied through nozzle.
Band wheel door interlocks.
Blade guards.
The saw is built to work in semi-automatic.
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2.2. B
LADE SPEED
The blade speed is controlled by an AC motor and a variable frequency drive, which allow to regulate the blade speed within a range of 20- 80 m/1’. Therefore the machine can cut both hard steels and aluminum. A digital reader constantly shows the blade speed .
2.5. V
ISES
Vises are hydraulic. The jaws are hardened
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3. HOW TO USE THE ISTRUCTIO MAUAL
3.1. Who should read the instruction manual? TAB 3.1 Who should read the manual
Description Operator Internal service Mechanical Electrical Instruction Manual Yes Yes No Electrical Schematic No No Yes
The electrical schematic is included in this manual and cannot be supplied separately.
3.1.
WHERE TO KEEP THIS MAUAL
This manual, that is provided along the machine in one copy, should be kept where the machine is located, in a safe and protected place, to be consulted if necessary.
3.3. Strength of this manual
1. This manual reflects the state of the art at the time the machine was built, and cannot be considered replaceable
by a newer version.
2. This manual has full force for all the life of the machine it goes along.
3. The customer is not allowed to copy totally or partially this manual to reach goals different than the one of the
original manual, and to avoid that a partial documentation replaces the original one.
MAUAL UPDATE
3.2.
The manufacturer does not have to update this manual if improvements are adopted on newer machines of the same kind of the one this manual make reference to.
This manual will be updated by the manufacturer only if :
this manual contains mistakes, errors, or something is missing;
the original machine is modified by the manufacturer.
Marginal errors or missing elements, if considered important for the correct work of the machine and its safe use will be immediately notified through an “Errata Corrige”.
To modify this manual the manufacturer will bring all the copy of the same edition back and then new copies will be sent to the customer.
The latest version is marked with higher letter (A, B....). The first edition is called “Edition A”.
3.3. H
OW TO OBTAI MORE COPIES
If necessary, the customer can obtain new copies of this manual simply making a written request and mentioning on it the machine serial number. If copies are requested, the manufacturer has the right to be paid to issue them.
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3.4. I
F THE MACHIE CHAGES OWER
If the original customer sales the machine, he/she should notify the manufacturer that the machine changed ownership, so to allow the manufacturer to inform the new user on the dangers and limits of liability.
3.5. S
UGGESTIOS
The customer should notify the manufacturer if improvements are necessary and where they are to increase an easy un­derstanding of this manual/
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4. LIABILITY LIMITS
The manufacturer cannot be responsible if the machine if used in one following ways , which are classified as inappro­priate :
4.1 I
APPROPRIATE USE OF THE MACHIE
It has to be considered inappropriate the use of the machine if :
••••
the safety rules are partially are completely unattended ;
••••
what the manufacturer prescribed is not done ;
the a danger or injury is due to an incorrect installation or assembly of the machine, and it was not done by the customer
or under his surveillance ;
wrong installation of protective equipment after maintenance or service ;
hydraulic or electrical problems due to the producer of the component and not to the producer of the machine ;
big deficiency in maintenance ;
modifications or maintenance on the machine without authorization of the manufacturer ;
use of atypical tools, other than the ones suggested by the manufacturer ;
use of non-original spare parts, other than the one suggested by the manufacturer ;
Partial or complete non-observance of the instructions ;
machine used by uninstructed operators without control of an expert operator ;
movement or machining of non-typical materials, or oversize and overweight materials compared to the ones indicated ;
natural calamities, including earthquakes, floods or others which could provoke danger or faults to the machine or its
structures easy to be identified ;
if electrical , pneumatic or mechanical safety features were partially or completely removed ;
maintenance while the machine is working;
when parts of the machine are tensioned using temporary connections, without protection or using faulty materials ;
a person without experience is within the danger area while the machine is running ;
a person with experience is within the danger area while the machine is running with the automatic cycle.
It has to be considered inappropriate also when the machine runs without enough surveillance to assure the operator safety or to assure that the machine can run properly.
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5. TYPE OF USE ALLOWED
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MACHIE ADDRESSEE
5.1.
This machine was design and built to comply a professional use, meaning that, besides the technical knowledge required, it is necessary to have a specific knowledge to operate the saw to obtain the required goals.
5.2. O
PERATOR
The saw operator should have experience on similar type of machine. People with low or none experience must be edu­cated, followed and watched by a supervisor with enough experience and ability.
Therefore, the operator must be aware about dangers related to the use of this machine, and dangers due to normal han­dling of metallic materials, similar, or heavy .
This machine cannot be used by people with handicaps or disables.
5.3. R
EGULATIO
Designing and building this machine we respected the following laws and rules :
UNI rules CEI rules
and more in detail, concerning the safety features (type A and B rules):
European Community Machine directive 89/392; CEI-EN 60204-1 and related rules concerning electrics, with respect of EC directive 73/23 ; EN 292/1 EN 292/2
If not clearly specified, every component used on this machine was UNI and CEI approved at the time it was bought or made.
5.4 T
YPICAL USE
This machine was designed and built to cut metallic materials fed by automatic systems and with overall size non larger than the ones listed in the chart below (5.4). The saw can move :
movement of the material before and after each cut ; vertical movement of the cutting bridge ; blade rotation.
All these movements could take place at the same time. The saw has the following performance :
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Tab. 5.4
Characteristic MIN MAX Cutting speed cmq/m 5 140 Material feeding speed Mt./m 30 300 Cutting bridge falling rate (w/o material) Mt./m 3 30 Bars size mm
Bar weight kg. 0 3000
5.5. L
IMITS USIG THE SAW
The machine has two limits of use due to :
operator’s inexperience material size and weight
The operator’s experience is particularly necessary when the saw runs in manual cycle ; material size and weight must be within the ones above shown.
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5.6. W
ORKABLE MATERIALS
This machine can cut only metallic bars, pipes and tubing. Every other use will is considered inappropriate use of the ma­chine.
5.7. W
ORK AREA
This machine has to work in industrial environment. It is design to make mechanical machining under human control, but the operator presence is not required continuously.
It is recommended to keep clean and free of interference the area close to the machine.
This machine use a mixture of oil and water as coolant liquid. Thus, the working area could be slippery and dirty.
5.8. W
ORK PLACE
The machine has one work place in front of the control panel.
A second temporary work place is aside the vises, the register them, and to change the blade.
Each work place must be easy to reach when necessary, without interference, even temporary. The machine can work automatically without operator, who must be present during the manual operations of loading and unloading, and control the control panel operations.
T
HIS AREA MUST BE MARKED BY AN APPROPRIATE SIGNAL
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No specific illumination is required, but the work place must be well illuminated to respect the requirements set by present safety rules. Only authorized people and maintenance personnel should be allowed to reach the saw work place.
The operator must be equipped with personal protection instruments, like gloves and safety glasses.
5.9. C
OMMAD MODES, STOP, EMERGECY STOP AD OUT OF SERVICE.
5.9.1 Command modes
The saw can be controlled in two different ways, turning or pressing a selector switch or a push-button (different ways for different models). The switch enable a relay which insert the manual mode.
Automatic mode ; the switch is on the automatic mode. All automatic commands are enable. Manual mode, the switch is on the manual mode. All the commands are switched to the control panel push-button
and switches.
5.9.1.1. Stop
The saw stops when the cutting cycle is over.
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5.9.1.2. Emergency stop
The emergency stop stops the machine removing tension from the control circuit.
5.9.1.3. Out of service
The saw can be turned out of service removing tension from the control circuit, switching off the main disconnect switch located on the front face of the enclosure. A signal saying “Out of service” must be placed on the machine, and it is oper­ator’s duty to verify that the machine cannot generate danger situations.
5.9.1.4. Safety precautions
The machine cannot generate danger situation when it is completely without electric or hydraulic power.
Concerning the electrical power, the machine must be completely disconnected from electrical sources, turning of the electrical socket on the building electrical panel. The machine cannot be considered completely safe if the only main dis­connect switch of the machine is turned off.
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6. TECHICAL DESCRIPTIO
6.1. M
ACHIE STRUCTURE
This saw is manly made by :
Base frame Cutting bridge Hydraulic power unit Control Panel Coolant system
Pos. Tab 6.1. Base frame
6.1.1. Base frame
6.1.4. Vices
6.1.1. Base frame
The machine frame is welded and machined. The material used is Fe 37. In the weldment there are two reservoirs, one for the coolant liquid, and the second for the hydraulic oil. The frame is machined to avoid corners or abrasive points that could be dangerous. It is painted with two layers of paint, the first of which prevent corrosion. It is machined to be assembled with other machine components.
6.1.4. Vices
It includes :
clamping vises, machined. Vises are controlled by hydraulic cylinders.
6.2.
CUTTIG BRIDGE
Pos. Tab 6.2 Cutting bridge
6.2.1 Cutting bridge frame
6.2.2 Guiding columns
6.2.3 Columns connection
6.2.4 Lifting cylinder
6.2.5 Blade tension assembly
6.2.6 Blade drive assembly
6.2.7 Band brush assembly
6.2.8 Left and right band guide
6.2.9
6.2.10 Wheels
6.2.11 Bland drive motor
6.2.1 Cutting bridge frame
The cutting bridge frame is a steel Fe37 weldment; it is machined to be assembled with other machine components. The bridge was design and built to endure the cutting strength, keeping enough sturdiness. The frame is mechanically machined and painted with anti-corrosion agents and with nitro paint. The blade is completely protected where it does not work. Covering the wheels, there are two doors that can be opened to change the blade. Two safety switches are mounted on these doors, so to stop the machine if the covers are not in posi­tion.
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The blade rotates on the wheels, one of which is driven, and the other one is idler.
6.2.2 Guiding columns
The columns guide vertically the cutting bridge movement. They are made with chrome bars, hardened and grinded.
6.2.3 Columns connection
Made using a Fe37 steel plate, the columns connection connects and makes the guiding columns sturdier. It is fastened to the columns through two bolts.
6.2.4 Lifting cylinder
This is an hydraulic cylinder, with chrome rod and lapped cylinder. The lifting cylinder is a double effect cylinder. The cy­linder head is attached to the cutting head, and the end head is fastened to the machine base frame.
6.2.5 Blade tension assembly
The C-M utilize an automatic band tension system. The proper band tension is assured by the cylinder. The system has been designed to guarantee a proper tensioning of the band. (see 15.4 Band replacement).
6.2.6 Band drive assembly
The band is powered by an AC motor which automatically regulates the cutting speed. The motor is directly flanged on the speed reducer: this application reduces vibration while providing best possible torque. On the other end of the reducer there is the drive wheel, that is fastened to the reducer.
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6.2.7 Band brush assembly
A band brush is powered by an hydraulic motor, and it cleans the teeth removing the chips.
6.2.8 Left and right band guides.
The band guides have to straighten the blade coming out the wheel, and keep it vertical helping the blade insertion be­tween the inserts.
Left guide arm : Moves horizontally on guides machined on the bridge, and it is moved by the movement of the vise. Right guide arm : Fixed on the cutting bridge. It supports the cutting servo control.
Both the guide arms have carbide inserts.
6.2.10 Wheels
They are mounted as follow :
the idler wheel is mounted on the band tension assembly and it turns on ball bearings ; the band drive wheel is mounted on the reducer shaft.
The wheels diameter is larger then the maximum material height that can be cut by the saw..
6.2.11 Band drive motor
The machine mounts a 15Kw, AC electric motor.
6.3. H
YDRAULIC POWER UIT
The power unit is located in an easy to service spot of the machine frame. The valve manifold and solenoids lays on the right side of the reservoir , over which the motor pump assemblies is installed. The power unit is made by :
Pos. Tab 6.3. Hydraulic power unit
6.3.1 Motor-pump assembly
6.3.2 Oil reservoir
6.3.3 Solenoid valves
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6.3.1 Motor-pump assembly
Electrical motor and pump are connected by an elastic coupling.
6.3.2 Oil reservoir
It is in the machine frame, and it has a maximum and a minimum level indicators, and a suction filter. On the left side of the infeed roller table there is a plug which allows to refill the reservoir. The hydraulic system has 2 filters :
a 250 micron 45 liters suction filter a 60 micron 45 liters outflow filter
These two filters have to be removed when changing the oil for the first time (after 500 working hours), washed using trichloroethane and dried blowing air.
6.3.3 Solenoid valves
The solenoid valves are mounted on blocks, and the control the hydraulic movements.
6.4.
ELECTRICAL SYSTEM
6.4.1 Control console
The control console is on the upper part of the control enclosure.
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6.4.2 Control enclosure
It is made bending metal sheets and it complies the IP55 standards. Inside there is the electrical panel which supports all the electrical devices (relays, circuit breakers,...) complying the CEI 60204.1 standards.
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7. MACHIE PROTECTIOS
This machine is entirely protected where it can be dangerous. Despite of this, there are some parts that cannot be pro­tected, and where the operator must never work. The biggest of these parts is where the blade touches material. There is a sticker close to every part which is not completely safe, to show to the operator that he should be extremely conscious.
8. HOW TO MOVE THE MACHIE
This machine, when installed and fastened to the ground must be considered a fix equipment. If it is necessary to move the machine or parts of it (because of maintenance or service), the operator must use a crank or a fork lift, or a lighter lifter with regards of the weight of the part that have to be lifted.
9. HOW TO ISTALL THE MACHIE
The machine can be installed by :
the manufacturer/distributor ; the customer ;
The machine is shipped completely mounted.
Moving the machine is one of the moment the risk of injuries is higher, thus it is important to make sure that :
Every operator wears the necessary safety equipment. The lifting equipment must be enough big to lift the machine. Always use only one lifting equipment to lift the ma-
chine, never combine more then one.
Do not use a lift fork if the length and width of the forks are inadequate to lift the machine. If using a crank, use metallic ropes and be sure they can support the weight of the machine. Put strong cartoon or
wood between the ropes and the machine. Never leave the ropes slide freely on the machine body.
Do not use metallic ropes if they show wear areas. Lift the machine slowly so to have enough time to adjust the lifting if necessary or to avoid obstacles. In the lifting area there should be enough people to move safely the machine, and do not allow anyone else to stay in
the lifting area during such operation.
Be sure that every movable part is well fastened to the machine. Remove or secure every part which falling can be
dangerous for the people in the work area.
Move the machine paying attention to the surrounding environment. Be extremely cautious so to avoid hitting any-
one or anything.
Moving the machine, stay as close as you can to the ground to avoid that a rope brake could generate dangers or se-
rious machine breaks.
If necessary, put pieces of wood under the machine base before putting it down.
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10. WHAT TO DO TO PREPARE THE MACHIE TO OPERATE
This machine can be installed by:
the manufacturer; a manufacturer representative ; the customer.
It is customer duty to get the place ready to install the machine, arranging also the anchor bolts to secure the machine on the ground.
To installed the machine it is necessary:
to be sure the place where the machine as to be placed is leveled; prepare the anchor bolts to secure the machine ; lift the machine and insert the anchor bolts ; Level the machine on the ground working on the leveling screws ;
The machine needs only to be electrically connected. Before to connect the power :
check if the operator uses the necessary safety devices ; check if the disconnect switch is insulated ; check if the control panel is insulated ; check if the fuses and circuit breakers are operative ; check the 3 phase electric source ; if the machine does not work properly, do not try to fix it, but immediately disconnect the power and ask for a main-
tenance expert ;
check the correct electrical connection ; check if the necessary protection devices work properly; check if push buttons and select switch work properly ; check the mechanical connections ;
The manufacturer cannot be responsible for injuries and/or damages due to the customer electric source, especial­ly if it does not meet the present safety requirements. (In Italy DLSG 94/626)
Check if the following motors rotate clockwise :
hydraulic power unit motor coolant pump band drive motor
The operator has to make sure:
1. That hydraulic oil and coolant fluid reservoirs are filled until the proper level.
2. The blade is installed (make reference to par. 15.4.)
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11. SAFETY DEVICES
11.1 L
IMIT SWITCHES AD SIGAL DEVICES
11.1.1. Limit switches
On the machine there are the following limit switches
D
ESIGNATION
FC1 Control cabinet FC2 Head down
FC3, FC4 Safety band wheel door interlock switches
FC5 Blade broken FC6 Head up
11.1.2. Speed reducer
Not necessary
11.1.3. Mechanical extra stroke
The following extra stroke mechanical protections are mounted:
Head down; Table forward.
D
ESCRIPTION
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11.1.4. Signals
See 12.1.2
11.1.5. Led, indicators and signals to avoid danger situations
Information about emergencies and dangerous situation concerning machine normal operations are shown. A red light in the electrical cabinet indicates that electrics are switched ON.
11.1.6. Protection devices
The blade is protected, where uncovered, by two guides that reduce the risk, but that cannot completely cover it.
11.2. F
IX PROTECTIOS
The movable parts of the machine are protected by fix covers, which can be removed using tools.
11.3. M
11.4. S
OVABLE PROTECTIOS
The wheels are covered by two removable doors which can be opened to inspect or replace the blade. Two safety inter­lock switches automatically stop the machine if the cover is opened while the machine is working.
AFETY FEATURES SET-UP
The limit switches are set up at the factory.
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12. MACHIE COTROLS
The manufacturer cannot be liable for any injury caused by errors or mistake using the machine, as described in the following paragraphs. The operator must wear all the personal protections equipments, as gloves and ear plugs.
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12.1. H
Machine can be can be configured with pushbuttons & selector switches or with the Saw1 con­trol. For machines equipped with the SAW1 control, please refer to paragraph 12.2
12.1.1 Control panel with pushbuttons & selector switches
OW TO OPERATE THE MACHIE
The control panel looks like the following drawing
CONTROLS DESCRIPTION
ST1 Blade speed readout
POT1 Blade speed adjusting knob
SR Coolant ON / OFF selector
SL Blade START - STOP
SCH Blade replacement selector
SGU Guidearm IN and OUT
SAR Cutting head up - down
SM Vice open - close
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PC Hydraulic power unit ON
PA Reset
Cutting cycle: when pressed, the vice closes, the blade starts and the head start mov-
PT
SRU Roller conveyor outfeed side, FWD - REV
SRC Roller conveyor infeed side, FWD - REV
PR Roller conveyor fast
EM Emergency pushbutton
H2 Hydraulic power unit overload
H3 Coolant overload
H4 Blade motor overload
ing down
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H5 Blade cover open
H6 Blade broken
H7 Emergency
H8 Blade replacement
H9 Spare
H10 Spare
12.1.2 To start the machine
To start the machine turn the main disconnect switch located on the front door of the electric­al cabinet on position (1). Press the reset pushbutton (PA) and the light will turn on. Enable machine movements by activating the power unit (PC).
12.1.3 To make a cut
- Position the material within the vice by mean of an overhead crane.
- Firmly clamp the bar by closing both set of vices (SM + SM2);
- Position the moveable guide arm as close as possible to material to cut;
- Adjust blade speed & feed control depending on material size and type;
- Start the cycle by pressing PT
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L
OADIG THE MATERIAL OTO THE MACHIE
Moving bars, especially if they are in bundles, it is necessary to pay attention to the security rules for the movement of heavy loads. Keep the bundle with steel strips until it is in the vises, then remove the strap before start­ing the cutting cycle.
12.1.4 To stop the machine
To shut the machine off, turn the main disconnect switch located on the front door of the elec­trical cabinet on position (0).
12.1.5 When an emergency occur
The emergency situation must be restored (i.e. Covers open alarm on: close the covers).Then press reset pushbutton (PA) and start the hydraulics again (pushbutton PC).
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12.2. H
12.2.1 Display
12.2.2 Standard controls
OW TO OPERATE MACHIES EQUIPPED WITH A SAW1 COTROL
First digit on the left (
1=manual 2=semiautomatic
Second digit from the left (_) shows head position:
= head down =head on fast approach =head up
If flashing indicates that blade is broken. The last 4 digits are used to display different informations, such as piece counter, blade speed, ...
3) shows machine status:
HEAD up / down
VICE open /close
START CYCLE to start semiautomatic cutting cycle
STOP CYCLE to stop semiautomatic cycle.
SCROLL to scroll different machine functions, such as piece counter or
blade speed. SHIFT to enable second key functions, shown on the upper left corner of the keys
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Hydralic's ON and OFF
To show blade speed
To select coolant status
Keyboard
F6 + Nr of cuts or blade speed F7 + Nr of cuts or blade speed
12.2.3 Piece counter
ICREMETAL = the control start counting cut pieces. DECREMETAL = the control, for each completed cut, de-count 1 piece from the amount to
be cut.
F6
F7


F7
Increase piece counter by one unit ( max allowed value 9999 ) Decrease piece counter by one unit ( min allowed value 0 ) Piece counter reset By doing this operation, the piece counter turn into incremental mode
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12.2.4 Coolant status
12.2.5 Menu scroll
The button
On
Coolant always ON
Coolant always OFF
Off
Coolant ON only when in cycle
Auto
allows to scroll the machine working parameters. Machine parameters are:
Piece counter
Blade speed
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Coolant status
Cycle mode
A red led lights up on the side of the selected menu.
12.2.6 Machine emergency codes
Machine, when an emergency occurs, displays an error code. Following you can find entire
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emergency descriptions list. To remove an emergency, press
Code Type Description
E001 Input Main emergency button E002 Input Overload relais E003 Input Overload relais E007 Input Blade broken E008 Input Open cover E009 Logic Hydraulic's OFF E010 Logic An Input does not allow cutting E012 Input Inverter fault E013 Logic Number of programmed pieces achieved E014 Input Head down E015 Input Head up E016 Input Head on fast approach E018 Logic Motor off E036 Logic Vice open E087 Logic Timeout cycle E091 Broken card Eeprom not working E095 Broken card Lost Eeprom memory ( Eeprom information ) E096 Broken card Lost Eeprom memory E097 Broken card Lost Eeprom memory ( configuration parameters)
12.3. H
Head feeding is controlled by a meterd feed valve located on the side of the control panel.
EAD FEEDIG COTROL
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13. CALIBRATIO AD TUE-UP
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13.1. C
13.2. M
13.3. B
ALIBRATIO
No calibration is needed, because the machine was calibrated by the manufacturer.
ACHIE TUIG-UP
No tuning-up is needed, because the machine was tuned-up by the manufacturer.
LADE MOTOR IVERTER
13.3.1 Control panel
All functions of the inverter can be controlled by way of the ACM-D2 control panel. The 4 input keys allow control of the motor and direct parameter programming. The functions are separated into three levels in order to facilitate programming (function tables TAB1, TAB2, TAB3).
TAB1 Programming of the basic parameters
of the inverter and call-up of works settings.
TAB2 Configuration of the analog and digi-
tal inputs, programming of the output voltage and of the SECURITY func­tion.
TAB3 Configuration of the analog and digi-
tal outputs, the extended setting func­tions and call-up of the diagnosis function.
B
UTTOS
D
Function interrogation forward.
Function interrogation back.
a) Jump back to the first function of the function table or sub-menu. b) Jump out of the table or sub-menu (starting from the first function of the function table or sub-menu).
Increments the parameter value of the selected function. To increase the speed at which scrolling through the value range takes place, keep IC depressed and briefly press DEC.
ESCRIPTIO
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Reduces the parameter value of the selected function.
13.3.2 Display
An eight-position alphanumeric display provides the user with all important information, such as inverter status messages and information on possible errors or faults and parameter setting values. The language for the display readout is selectable.
13.3.3 Help - function and language - selection
When pressing SHIFT and INC, on the display appears a scrolling Help-text concerning the cur­rently active function. Releasing INC and pressing DEC while holding SHIFT inverts the text scroll - direction. Pressing SHIFT and INC in TAB1, funct. 1 enters the language - select mode. Select the language by pressing the corresponding key.
Italian German English
The selected language will be saved automatically. Press any key to return to TAB1, funct. 1.
To increase the speed at which scrolling through the value range takes place, keep DEC depressed and briefly press IC. Permits access to a sub-menu or a parameter table.
Help function: A Help text can be called for each function. A key change from IC to DEC with depressed SHIFT key inverts the text scroll-direction of the help text. Software reset.
SELECT IC DEC
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13.3.4 Inverter status M
ESSAGE
OFF No EABLE, terminals 10/11 open.
STOP
1 33.6Hz
JOG
DEFAULT
SECUR. 1 SECUR. 2
Dyn Brake
DC STOP
FreqScan
D
If the AUTOSTART function is deactivated, the inverter is stopped af­ter switching on (see TAB3, SUB XPAR, function SW7 = OFF). Acti­vate EABLE or START/STOP to start the inverter. Display of current actual values or changeable parameters (the first number group indicates the function number and the 2nd number group the value of the respective parameter). JOG mode is activated; output frequency setting by means of the unit keypad. Default parameter values (works setting) have been loaded but not saved. SECURITY Level 1 is activated; parameter values cannot be saved. SECURITY Level 2 is activated; parameter values can be neither changed nor saved. Switching on braking chopper. DC brake is activated. ACM - Synchronizer: the inverter measures the actual motor frequency.
ESCRIPTIO
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13.3.5 Warnings
M
ESSAGE
Undervol Overload
HYST
RAMP
Br_limit
MPtFault
Overtemp
Ot_motor
D
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ESCRIPTIO
The mains has been reached the Under voltage Limit. The output current has almost reached the type-specific limit The set limit value for the output current has been exceeded. The output frequency is reduced step-by-step until the output current falls below the limit value again (see TAB1, SUB IMOT, function S-INT =4). The set limit value for the output current has been reached. The acceleration ramp is stopped (see TAB1, SUB IMOT, funct. S-INT = 3). The dynamic braking power is near the programmed limit (configurable by TAB2, func. BrLim). This message can be signalized by the relays or the open collector outputs. (TAB3, funct. REL, OC1, OC2) Motor potentiometer function: it was enabled a preset frequency with a motor rotation sense different of the actual. The output frequency re­mains unchanged (TAB1 funct. JOG = MPt). (Only with Softw. D2A­STD) The inverter (heat sink) temperature reaches the limit value. (Only with Softw. D2A-STD) The motor temperature reaches the limit value. (Only with Softw. D2A-STD)
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13.3.6 Operating error messages
M
ESSAGE
UDERVOL OVERVOLT OVERLOAD OVERTEMP
ILIMIT
1<4Ma
Br_limit
Ot_motor
1. Inverter stopped. Automatic error reset as soon as the link voltage rises above the under vol-
tage value.
2. Inverter stopped. If the AUTORESET function is activated (see TAB3, SUB XPAR, function
SW3), a reset is possible by setting or the START/STOP input, or the EABLE input, or by setting the set point to zero.
3. The motor is decelerated with the deceleration ramp and the inverter is stopped. An error re-
set can be performed as described in Item 2.
4. The motor is decelerated with the deceleration ramp and the inverter is stopped until the tem-
perature doesn’t fall below the limit value. If the AUTORESET function is activated (see TAB3, SUB XPAR, function SW3), a reset is possible by setting or the START/STOP in­put, or the EABLE input, or by setting the set point to zero.
5. Behavior with Softw. D2A-STD: see 4) Behavior with Softw. D2A-1300: see 2)
D
Under voltage has been detected in the link. The voltage in the link has reached the over voltage value. The output current has exceeded the type-specific limit value. The inverter (heat sink) temperature is too high. The set limit value for the output current has been exceeded (see TAB1, SUBIMOT, S-INT = 1 or 2). The speed reference line is interrupted or the set point is less than 4 mA. The dynamic braking power has reached its programmed limit. The motor temperature has been reaching the limit value for more than 7 seconds. (Only with Softw. D2A-STD)
ESCRIPTIO
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13.3.7 Hardware error messages
An error which is established during the self-test phase or during operation is shown on the dis­play by the message ‘‘ERROR’’ together with an error number. The inverter is stopped by the safety devices. To reset the error message, switch off the mains supply and switch back on again. If the error is not rectified by this, send the unit to the after-sales service for inspection.
RROR
E
ERROR 1 Data error Reprogram parameters. ERROR 2 Hard- and software is not compatible ERROR 3 CPU error ERROR 4 Keypad error ERROR 5 Error in ROM ERROR 6 Watchdog error ERROR 7 Clock error ERROR 8 Program error ERROR 9 Output stage error
C
AUSE
Have unit checked by technical after-sales service.
REMEDY
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13.3.8 Programming structure
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14. DISMATLIG OF THE MACHIE
Only experts can dismantle the machine. It is important to require the dismantle to the constructor, especially if the plant has to be reposi­tioned. Besides it is important to verify with the constructor the conditions to respect the security and health requirements.
15. ORDIARY PROBLEMS
WARIG
It is defined as ordinary service the maintenance due to breaks or wear of parts. Even in these circumstances, only expert operators should service the saw. They have to be able to work safely knowing which are the machine dangers, and avoiding unnecessary risks. WHEN SERVICING THE SAW, ALWAYS DISCONNECT THE ELECTRIC SOURCE. THE OPERATOR MUST USE THE ENTIRE SAFETY EQUIPMENT (GLOVES, GLASSES AND BOOTS). The user must wear all the necessary protection devices: gloves, glasses and shoes.
THE MAUFACTURER CA OT BE JUDGED LIABLE FOR IJURIES OR DAMAGES DUE TO UATTEDED SAFETY RULES BY THE USER.
15.1. B
15.2. C
ASE
15.1.1. Base
Base dwg. 210/01-001
Vise wear status 06-012 Replace vise inserts 06-012 Vise guide 06-008
UTTIG BRIDGE
15.2.1 Columns
Check locknuts 01-025 Spanner
15.2.2 Connection bar
Check hydraulic hoses none
15.2.3 Lifting cylinder
Column dwg. 210/01-024 Pos. Tool
Head connection bar. 210/01-032
Lifting cylinder dwg. 210/12
Pos.
Pos.
Pos.
Tool
Tool
Tool
Check locknuts 12-017 Spanner Check gaskets None
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Check the blade position on the wheel. If the blade back touches the wheel, call the
STRUCTIO & PARTS MAUAL
15.2.4 Blade tension assembly Blade tension assembly Dwg. 210/16 Pos. Tool
Adjust the guide track Spanner Check locknut 03-052 Do not regulate the central screw of the blade tension guide
15.2.5 Band drive assembly
Band drive assembly dwg. 210/03 Pos. Tool
Check the electrical motor 03-001 Check the collect locking that connect the wheel to the reducer shaft 03-043 Check belts 03-019
15.2.6 Guide arms
Check guide arms dwg. 210/05 Pos. Tool
Check carbide inserts 05-045 When changing the blade, clean the inserts with gasoline Check, and if necessary replace, the guiding ball bearings and the guide-arm inserts 05-023
05-026-029
Check and rotate the carbide backer 17-003
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15.2.7 Band brush assembly
Band brush assembly dwg. 210/20 Pos. Tool
Check and if necessary replace the band brush 20-014 Spanner Register the brush so to keep the blade teeth always clean
15.2.8 Wheels
Wheel. 03-042-0 Pos. Tool
Check the wheel adjustment
03-042 Manufacturer manufacturer. Check and keep clean the wheel grooves 03-042 Be sure the blade is not cutting the machine frame 03-042 Manufacturer Keep lubricated all the bearings 03-051
15.2.9 Servo-cutting device Servo cutting assembly Dwg. 066/17 Pos. Tool
Check the servo-valve adjusting the cutting pressure. Turn the knob Open the servo-valve cover and check the vertical movement of the unit. Spanner
15.4 H
YDRAULIC POWER UIT
Keep the pressure to 50 bar. Check the reservoir level and, if necessary, add oil type OSO46.
15.5 E
LECTRIC COTROL PAEL
Replace, if necessary, broken components.
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16. MAITEACE
LUBRICATIO
16.1
Reducer A Loading plug B Level C Unloading plug
Columns D Loading plug E Level
Wheel F Bearings
Hydraulic power unit G Loading plug H Unloading plug
AGIP BLASIA 150 ESSO SPARTAN EP 150 MOBILGEAR 632 BP ENERGOL GR-XP150 FIA GIRA 150
AGIP EXIDIA 68 BP ENERGOL HP 60-C TOTAL CARTER EP 68
AGIP GR MU 2 BP MACH-GREASE LT2 TOTAL MULTIS MS
AGIP OSO 46 FIA HYDRAN 46 BP ENERGOL HLP 46 ESSO NUTO H 46 TOTAL AZOLLA 46
Replace oil after first 100 hours Check the level every 2000 hours Replace every 4000 hours
Check weekly
Check weekly
Replace oil after first 500 hours Check the level every 500 hours Replace every 2000 hours
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16.2. P
ROBLEMS
Problems Reasons How to solve the problem
Twisted cut Feed rate
Blade is not perpendicular The blade looses the sharp­ness quickly The blade vibrates
Blade teeth break Feed rate
Blade breaks The guides don’t work properly
Stripes on a side of the blade Only one guide guides the blade Regulate the guides Blade stalls Feed rate Reduce the feed rate The motors are off Problems with the electric source
Cutting speed
Wrong teeth
The blade slides on the material
Feed rate
Wrong teeth
Cutting speed
The cut begins on an irregular or thin section
Material unclamped
Blade in tension even when work is over
Wrong weldment
Blade installed incorrectly
Wrong circuit breakers
Short circuit
Reduce the feed rate Register the blade Reduce the speed Use a blade with the right teeth Increase the feed rate Increase the band tension Reduce the feed rate Use a blade with the right teeth Reduce the speed Turn the material on the machine Clamp the material Check the guides and their carbide inserts Remove tension when not working Return the blade to the supplier Check the blade
Look for the problem and solve it
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BLADE REPLACEMET
16.3.
1. Turn the electric power off, and unplug the source.
2. Wear the protection gloves.
3. Turn the band tension valve handle so to remove tension to the blade.
4. Open both the band wheel doors.
5. If stalling in a bar, remove the blade slowly.
6. It is suggested to cover the blade using the plastic teeth strip was originally on the blade.
7. Take the old blade in a place where no one can be injured.
8. Clean using compressed air the wheel tracks and the band guides.
9. Put the new blade on the wheel paying attention to the teeth orientation.
10. Make sure the blade sits completely on the wheel track.
11. Tension the blade little by little, and check that it sits correctly on the track.
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17. REMAIIG DAGERS
This machine is powered by electrical power. The manufacturer, building the machine, used the state of the art solutions also meeting the regarding regulations to assure maximum safety to the operator.
When servicing the machine with power on to check particular electrical components, always respects the basic safety rules. Reduce as much as possible this type of operations.
The customer is required to provide a suitable power source respecting the CEI 64-8 or other countries special rules where the machine was installed.
18. PERSOEL TRAIIG
This machine was design to be easily operated. It is not expressly required an expert to operate the saw, but an expert can set as best as possible the machine so to obtain the maximum results.
Therefore, the operator needs a good experience in machine tools, especially in band saw machine.
The internal maintenance personnel should be able to read and understand an electrical and hydraulic schematic, and work on the machine following the instructions contained in the schematics.
19. MACHIE DISMATLE
This machine was built using only ecological materials. It is necessary to separately recycle only the hydraulic oils and the coolant liquid.
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This band saw machine:
YPE
S
T
Exhibit A – Proof of test
ERIES
S
ERIAL UMBER
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C- 102 M
Has been tested in accordance with the following norms:
UNI-EN 292-1 UNI-EN 292-2 CEI 60204-1 (CEI 44-5)
The test had positive result as per testing sheet #
Hours of hydraulic power unit for testing purpose
Numbers of cuts done for test purpose
Electrical test
Hydraulic test
Mechanic test
27292
Check
Signed
Vanzago, _____________ ISTech Segatrici S.r.l.
Vanzago (MI)
Italy
A
OALL EUROPEAN FACTORY MANAGER
D
LESSANDRO RESCALDANI
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