Bomar Individual automatic series User manual

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Series Individual Automatic

Individual 520.360 DGA

2300

Operating instructions

Before transporting and using the machine,

please read the instructions thoroughly!

Seriové číslo / Serien Nummer / Serial Number ___________________

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2 Manual version: 1.12 / Mar. 2012

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: [email protected]

www: http://www.bomar.cz

We are available:

Mondays to Fridays 700 – 1600

Version:

1.12 / Mar. 2012

rev. 1

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

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Content

1.SAFETY NOTES ........................................................................9

1.1.Machine determination.......................................................................................................................................................11

1.2.Protective suit and personal safety.............................................................................................................................. 11

1.3.Safety notes for machine operator .............................................................................................................................. 12

1.4.Safety notes for the servicing and repairs ...............................................................................................................12

1.5.Safety notes for the servicing and repairs on hydraulic unit....................................................................... 13

1.6.Safety machine accessories .............................................................................................................................................. 13

1.6.1.Total Stop..............................................................................................................................................................................................13

1.6.2.Protected space around saw....................................................................................................................................................14

1.6.3.Arm covers ...........................................................................................................................................................................................14

1.6.4.Saw band stretching and rupture inspection ...............................................................................................................15

1.6.5.Band saw cover .................................................................................................................................................................................15

1.7.Safety notes for the cooling ............................................................................................................................................. 15

1.7.1.Instructions for first help .............................................................................................................................................................15

1.7.2.Safety information for the chip remover..........................................................................................................................16

1.8.Umístění štítku stroje / Maschinenschild position / Position of machine label.............................. 16

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

symbols.......................................................................................................................................................................................... 17

2.MACHINE DOCUMENTATION................................................19

2.1.Technická data / Technische Daten / Technical data ......................................................................................21

2.2.Rozměrové schéma / Aufstellzeichnung / Installation diagram – 1....................................................... 23

2.3.Popis / Beschreibung / Description – 1 .................................................................................................................... 24

2.4.Popis / Beschreibung / Description – 2 .................................................................................................................... 25

2.5.Transportation and stocking............................................................................................................................................26

2.5.1.Conditions for transportation and stocking...................................................................................................................26

2.5.2.Transport and stocking preparations..................................................................................................................................26

2.5.3.Transport and stocking ................................................................................................................................................................26

2.5.4.Transportní schéma / Transport schema / Transport diagram – 1...............................................................27

2.5.5.Transportní schéma / Transport schema / Transport diagram – 2...............................................................28

2.5.6.Activation..............................................................................................................................................................................................28

2.5.7.Machine working conditions ...................................................................................................................................................29

2.6.Band saw unpacking and assembling ....................................................................................................................... 29

2.6.1.Machine installing and levelling ............................................................................................................................................29

2.6.2.Machine disposal after lifetime...............................................................................................................................................29

2.6.3.First run of the power pack.......................................................................................................................................................30

2.6.4.Filling the reservoir with hydraulic oil ................................................................................................................................30

2.6.5.Kotevní plan / Verankerungsplan / Grounding plan ................................................................................................31

2.7.Electrical connection............................................................................................................................................................. 32

2.7.1.Check the direction of the saw band..................................................................................................................................32

2.7.2.Check machine connection into electrical network.................................................................................................33

2.8.Filling of the cooling system............................................................................................................................................ 33

2.9.Check machine function .................................................................................................................................................... 33

2.10.Saw band.......................................................................................................................................................................... 33

2.10.1.Saw band size.....................................................................................................................................................................................33

2.10.2.Selection of the saw band tooth system..........................................................................................................................33

2.10.3.Saw band running-in.....................................................................................................................................................................34

2.10.4.Tables for teeth selection ...........................................................................................................................................................34

3.MACHINE CONTROL..............................................................37

3.1.Starting the Band Saw..........................................................................................................................................................39

3.2.Control panel ............................................................................................................................................................................. 40

3.2.1.Control board .....................................................................................................................................................................................40

3.2.2.Touch screen.......................................................................................................................................................................................41

3.3.Controlling the Machine.....................................................................................................................................................42

3.3.1.Controlling the Touch Display ................................................................................................................................................42

3.3.2.Moving in the Chosen Menu ...................................................................................................................................................42

3.4.Referencing the Machine...................................................................................................................................................43

3.5.Machine modes........................................................................................................................................................................ 43

3.6.Manual Regime.........................................................................................................................................................................43

3.6.1.Semi-automatic Cut .......................................................................................................................................................................44

3.6.2.Automatic Positioning..................................................................................................................................................................45

3.7.Automatic Regime.................................................................................................................................................................. 47

3.7.1.Automatic Regime Screen.........................................................................................................................................................47

3.7.2.Starting the Automatic Cycle...................................................................................................................................................47

3.7.3.Starting automatic cycle .............................................................................................................................................................48

3.7.4.Automatic Material Feed.............................................................................................................................................................49

3.8.Entering Cutting Data........................................................................................................................................................... 50

3.8.1.Choosing the Cutting Program..............................................................................................................................................50

3.8.2.Entry Table for the Current Cutting Program................................................................................................................51

3.8.3.Cutting Commands Editor.........................................................................................................................................................52

3.8.4.More cuts...............................................................................................................................................................................................53

3.9.Disrupting a Cycle................................................................................................................................................................... 55

3.9.1.Pausing the Running .....................................................................................................................................................................55

3.9.2.Emergency Stop During an Automatic Cutting Cycle ............................................................................................55

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6 Manual version: 1.12 / Mar. 2012

Manual rev.: 1

3.9.3.Out of Material .................................................................................................................................................................................. 56

3.9.4.End of the Cutting Program..................................................................................................................................................... 56

3.10.Saw Settings................................................................................................................................................................... 56

3.10.1.User Parameters ............................................................................................................................................................................... 58

3.10.2.F3 – Service Parameters .............................................................................................................................................................. 59

3.10.3.F5 – Feeder Parameters............................................................................................................................................................... 59

3.10.4.F7 – System Parameters.............................................................................................................................................................. 60

3.10.5.F2 – Arm Parameters..................................................................................................................................................................... 61

3.10.6.F4 – Feeder length measurement........................................................................................................................................ 62

3.10.7.F6 – Save settings to memory................................................................................................................................................. 63

3.10.8.F8 – Load settings from memory.......................................................................................................................................... 63

3.10.9.F9 – Machine parameters .......................................................................................................................................................... 63

3.11.Error statements .......................................................................................................................................................... 64

3.11.1.Frame bottom stop position setting .................................................................................................................................. 66

3.11.2.Setting of optimum distance of the guiding cubes................................................................................................. 66

3.11.3.Saw frame lift stop setting......................................................................................................................................................... 66

3.11.4.Brush setting....................................................................................................................................................................................... 67

3.12.Material insertion ........................................................................................................................................................ 68

3.12.1.Handling agent selection........................................................................................................................................................... 68

3.12.2.Insertion................................................................................................................................................................................................. 68

3.12.3.Bundle material cutting .............................................................................................................................................................. 68

4.MACHINE MAINTENANCE .....................................................69

4.1.Saw band installation and dismantling..................................................................................................................... 71

4.1.1.Saw band dismantling – mechanical saw band stretching ................................................................................ 71

4.1.2.Saw band dismantling – hydraulical saw band stretching.................................................................................. 72

4.1.3.Saw band installation ................................................................................................................................................................... 72

4.2.Saw band stretching and inspection.......................................................................................................................... 73

4.2.1.Saw band stretching..................................................................................................................................................................... 73

4.2.2.Saw band inspection .................................................................................................................................................................... 73

4.2.3.Saw band run setting ................................................................................................................................................................... 74

4.2.4.Adjusting of the limit switch of the saw band stretching.................................................................................... 74

4.3.Cooling agents and chips disposal.............................................................................................................................. 75

4.3.1.Coolant device inspection......................................................................................................................................................... 75

4.3.2.Chips disposal.................................................................................................................................................................................... 75

4.4.Hydraulic, Greases and oils................................................................................................................................................ 76

4.4.1.Gearbox oils ........................................................................................................................................................................................ 76

4.4.2.Lubricant greases............................................................................................................................................................................ 76

4.4.3.Lubrication........................................................................................................................................................................................... 77

4.4.4.Hydraulic oils...................................................................................................................................................................................... 78

4.4.5.Hydraulic unit service ................................................................................................................................................................... 79

4.4.6.Hydraulic oil level check ............................................................................................................................................................. 80

4.4.7.Manometers........................................................................................................................................................................................ 80

4.5.Machine cleaning.................................................................................................................................................................... 81

4.6.Worn pieces replacement ................................................................................................................................................. 81

4.6.1.Pushing bearing replacement................................................................................................................................................ 81

4.6.2.Saw band guiding pulleys replacement.......................................................................................................................... 85

4.6.3.Hard metal guides replacement............................................................................................................................................ 87

4.6.4.Brush replacement ......................................................................................................................................................................... 89

5.TROUBLESHOOTING .............................................................91

5.1.Mechanical problems........................................................................................................................................................... 93

5.2.Electric and hydraulic problems.................................................................................................................................... 95

5.3.Hydraulic problems................................................................................................................................................................ 96

6.SCHÉMATA / SCHEMAS / SCHEMATICS ...............................97

6.1.Elektrické schema / Elektroschema / Wiring diagrams – 3×400 V, TN-C-S ........................................ 98

6.2.Hydraulické schéma Hydraulisches Schéma Hydraulic diagram – Individual 520.360 DGA 122

6.3.Hydraulické schéma Hydraulisches Schéma Hydraulic diagram – 2 ...................................................124

7.VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ /

ZEICHNUNGEN FÜR BESTELLUNG DER ERSATZTEILE / DRAWING

ASSEMBLIES FOR SPARE PARTS ORDER .....................................127

7.1.Individual 520.360 DGA.....................................................................................................................................................128

7.2.Kusovník / Stückliste / Piece list – Individual 520.360 DGA........................................................................129

7.3.Trať / Bahn / Conveyor.......................................................................................................................................................132

7.4.Kusovník / Stückliste / Piece list – Trať / Bahn / Conveyor ........................................................................133

7.5.Podavač / Vorschub / Feeder........................................................................................................................................134

7.6.Kusovník / Stückliste / Piece list – Podavač / Vorschub / Feeder..........................................................135

7.7.Podavač / Vorschub / Feeder........................................................................................................................................136

7.8.Kusovník / Stückliste / Piece list – Podavač / Vorschub / Feeder..........................................................137

7.9.Váleček / Rolle / Cylinder..................................................................................................................................................138

7.10.Kusovník / Stückliste / Piece list – Váleček / Rolle / Cylinder.......................................................139

7.11.Horní upínání /Obere Spannung / Top clamping...............................................................................140

7.12.Váleček / Rolle / Cylinder 1 .................................................................................................................................141

7.13.Váleček / Rolle / Cylinder 2 .................................................................................................................................142

7.14.Váleček / Rolle / Cylinder 3 .................................................................................................................................143

7.15.Rameno / Sägerahmen / Saw arm.................................................................................................................146

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7.16.Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm ................................. 147

7.17.Rameno / Sägerahmen / Saw arm................................................................................................................ 148

7.18.Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm ................................. 149

7.19.Napínání pásu/ Sägebandspannung / Saw band tensing............................................................ 150

7.20.Kusovník / Stückliste / Piece list – Napínání pásu/ Sägebandspannung / Saw band

tensing......................................................................................................................................................................................... 151

7.21.Vedení pásu / Sägebandführung / Saw band guiding.................................................................... 152

7.22.Kusovník / Stückliste / Piece list – Vedení pásu / Sägebandführung / Saw band

guiding........................................................................................................................................................................................ 153

7.23.Vodící kostka / Führungsklotz / Guiding Cube 1................................................................................ 154

7.24.Kusovník / Stückliste / Piece list – Vodící kostka / Führungsklotz / Guiding Cube 1 . 155

7.25.Vodící kostka / Führungsklotz / Guiding Cube 2................................................................................ 156

7.26.Kusovník / Stückliste / Piece list – Vodící kostka / Führungsklotz / Guiding Cube 2 . 157

7.27.Pohon / Antrieb / Drive........................................................................................................................................ 158

7.28.Podstavec / Untersatz / Base............................................................................................................................ 160

7.29.Kusovník / Stückliste / Piece list – Podstavec / Untersatz / Base.............................................. 161

7.30.Svěrák / Schraubstock / Vice............................................................................................................................. 162

7.31.Kusovník / Stückliste / Piece list – Svěrák / Schraubstock / Vice .............................................. 163

7.32.Svěrák / Schraubstock / Vice – 2 .................................................................................................................... 164

7.33.Kusovník / Stückliste / Piece list – Svěrák / Schraubstock / Vice – 2...................................... 165

7.34.Konzola otočná / Drehkonsole / Turnable consol .............................................................................. 166

7.35.Kusovník / Stückliste / Piece list – Konzola otočná / Drehkonsole / Turnable consol 167

7.36.Pohon / Antrieb / Drive........................................................................................................................................ 168

7.37.Kusovník / Stückliste / Piece list – Pohon / Antrieb / Drive ......................................................... 169

7.38.Sloup / Säule / Pillar 1 ........................................................................................................................................... 170

7.39.Kusovník / Stückliste / Piece list – Sloup / Säule / Pillar 1 ............................................................. 171

7.40.Sloup / Säule / Pillar 2 .......................................................................................................................................... 172

7.41.Kusovník / Stückliste / Piece list – Sloup / Säule / Pillar 2 ............................................................. 173

7.42.Brzda / Bremse / Brake.......................................................................................................................................... 174

7.43.Odměřování / Gehrungsmessung / Measuring................................................................................... 175

7.44.Kusovník / Stückliste / Piece list – Odměřování / Gehrungsmessung / Measuring..... 176

7.45.Kartáček / Bürste / Brush ..................................................................................................................................... 177

7.46.Kusovník / Stückliste / Piece list – Kartáček / Bürste / Brush....................................................... 178

7.47.Propojovací díl / Verbindungsteil / Connecting part ...................................................................... 179

7.48.Váleček / Rolle / Roller .......................................................................................................................................... 180