Bomar Ergonomic 320.250 DGS User manual

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Series Ergonomic
Ergonomic 320.250 DGS
Operating instructions
Before transporting and using the machine,
please read the instructions thoroughly!
Seriové číslo / Serien Nummer / Serial Number ___________________

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2 Manual version: 1.02 / Mar. 2010
Manual rev.: 1
Service and information
Your BOMAR dealer
:
Direct BOMAR contact:
BOMAR spol. s r.o.
Těžební 1236/1
62700 Brno
Czech Republic, EU
telefon: +420 – 533 426 100
fax: +420 – 533 426 109
e-mail: [email protected]
www: http://www.bomar.cz
We are available:
Mondays to Fridays 700 – 1600
Version:
1.02 / Mar. 2010
rev. 1
BOMAR, spol. s r.o. ©– Subject to modifications and amendments.

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Content
1.SAFETY NOTES ........................................................................7
1.1.Machine determination..........................................................................................................................................................9
1.2.Protective suit and personal safety.................................................................................................................................9
1.3.Safety notes for machine operator .............................................................................................................................. 10
1.4.Safety notes for the servicing and repairs ...............................................................................................................10
1.5.Safety machine accessories .............................................................................................................................................. 11
1.5.1.Total Stop..................................................................................................................................................................11
1.5.2.Arm cover .................................................................................................................................................................11
1.5.3.Band saw cover.....................................................................................................................................................11
1.5.4.Saw band stretching and rupture inspection ...................................................................................11
1.6.Safety notes for the cooling .............................................................................................................................................12
1.6.1.Instructions for first help .................................................................................................................................12
1.7.Umístění štítku stroje / Maschinenschild position / Position of machine label.............................. 12
1.8.Umístění bezpečnostních značek / Verteilung der Sicherheitszeichen / Position of safety
symbols.......................................................................................................................................................................................... 13
2.MACHINE DOCUMENTATION................................................15
2.1.Technická data / Technische Daten / Technical data ...................................................................................... 17
2.2.Rozměrové schéma / Aufstellzeichnung / Installation diagram...............................................................18
2.3.Popis / Beschreibung / Description.............................................................................................................................19
2.4.Transportation and stocking............................................................................................................................................20
2.4.1.Conditions for transportation and stocking.......................................................................................20
2.4.2.Transport and stocking preparations......................................................................................................20
2.4.3.Transport and stocking....................................................................................................................................20
2.4.4.Transportní schéma / Transport schema / Transport diagram............................................21
2.5.Activation...................................................................................................................................................................................... 22
2.5.1.Machine working conditions .......................................................................................................................22
2.6.Band saw unpacking and assembling .......................................................................................................................22
2.6.1.Machine installing and levelling ................................................................................................................24
2.6.2.Machine disposal after lifetime...................................................................................................................24
2.6.3.Kotevní plan / Verankerungsplan / Grounding plan.....................................................................25
2.7.Electrical connection............................................................................................................................................................. 26
2.7.1.Check the direction of the saw band......................................................................................................26
2.8.Filling of the cooling system............................................................................................................................................ 26
2.9.Check machine function .................................................................................................................................................... 27
2.10.Saw band.......................................................................................................................................................................... 27
2.10.1.Saw band size .................................................................................................................................................27
2.10.2.Selection of the saw band tooth system.......................................................................................27
2.10.3.Saw band running-in .................................................................................................................................27
3.MACHINE CONTROL..............................................................29
3.1.Main switch .................................................................................................................................................................................31
3.2.Control elements.....................................................................................................................................................................31
3.2.1.Ergonomic 320.250 DGS without frequency converter..............................................................31
3.2.2.Ergonomic 320.250 DGS with frequency converter......................................................................32
3.3.Machine control .......................................................................................................................................................................33
3.3.1.Cutting........................................................................................................................................................................33
3.3.2.Setting of the material length .....................................................................................................................33
3.3.3.Cutting speed adjustment.............................................................................................................................34
3.3.4.Angular cut setting.............................................................................................................................................34
3.4.Material insertion..................................................................................................................................................................... 35
3.4.1.Handling agent selection...............................................................................................................................35
3.4.2.Insertion.....................................................................................................................................................................35
3.4.3.Bundle material cutting...................................................................................................................................35
4.MACHINE SERVICE ................................................................37
4.1.Saw band dismantling ......................................................................................................................................................... 39
4.2.Saw band installation............................................................................................................................................................ 40
4.3.Saw band stretching and inspection.......................................................................................................................... 41
4.3.1.Saw band stretching..........................................................................................................................................41
4.3.2.Saw band inspection.........................................................................................................................................41
4.4.Adjustment.................................................................................................................................................................................. 42
4.4.1.Saw band petting................................................................................................................................................42
4.4.2.Hard metal guides adjustment...................................................................................................................42
4.4.3.Guide cube adjustment...................................................................................................................................43
4.4.4.Brush adjustment ................................................................................................................................................43
4.4.5.Angular stops adjustments ...........................................................................................................................44
4.4.6.Adjusting the limit switch of the saw band stretching...............................................................44
4.4.7.Saw frame lower position stop adjustment .......................................................................................45

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4.4.8.Adjustment of the limit switch of saw frame lower stop point.............................................45
4.5.Cooling agents and chips disposal.............................................................................................................................. 46
4.5.1.Coolant device inspection.............................................................................................................................46
4.5.2.Cooling liquid preparation¨ ..........................................................................................................................46
4.5.3.Chips disposal........................................................................................................................................................47
4.6.Greases and oils........................................................................................................................................................................ 47
4.6.1.Gearbox oils.............................................................................................................................................................47
4.6.2.Lubricant greases ................................................................................................................................................48
4.6.3.Lubrication...............................................................................................................................................................49
4.6.4.Hydraulic oils ..........................................................................................................................................................49
4.6.5.Hydraulic oil level check..................................................................................................................................50
4.6.6.Adjustment of a throttle valve....................................................................................................................50
4.7.Machine cleaning.................................................................................................................................................................... 51
4.8.Worn pieces replacement ................................................................................................................................................. 51
4.8.1.Hard metal guides replacement................................................................................................................51
4.8.2.Saw band guiding rollers replacement.................................................................................................52
4.8.3.Round brush replacement ............................................................................................................................53
4.8.4.Stretching wheel replacement...................................................................................................................54
4.8.5.Driving wheel replacement ..........................................................................................................................56
4.8.6.Cooling pump replacement.........................................................................................................................57
5.ZÁVADY / TROUBLESHOOTING ............................................59
5.1.Mechanical problems........................................................................................................................................................... 61
5.2.Electric problems..................................................................................................................................................................... 63
6.SCHÉMATA / SCHEMAS / SCHEMATICS ...............................65
6.1.Elektrická schémata / Elektroschemas / Wiring diagrams – bez frekv. měniče / ohne
Frequenzumrichter / without frequency convertor – 3×400 V/50 Hz, TN-C-S................................ 67
6.2.Elektrické schema / Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F,
3×400 V TN-C-S......................................................................................................................................................................... 71
6.3.Elektrické schema / Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F,
3×400V TN-C .............................................................................................................................................................................. 74
6.4.Elektrické schema / Elektroschema / Wiring diagrams – Erg. 320.250 G-F/DG-F/DGS-F,
3×230 V.......................................................................................................................................................................................... 78
6.5.Hydraulické schéma Hydraulisches Schéma Hydraulic diagram.............................................................. 82
7.VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ /
ZEICHNUNGEN FÜR BESTELLUNG DER ERSATZTEILE / DRAWING
ASSEMBLIES FOR SPARE PARTS ORDER .......................................83
7.1.Ergonomic 320.250 DGS..................................................................................................................................................... 84
7.2.Kusovník / Stückliste / Piece list – Ergonomic 320.250 DGS....................................................................... 85
7.3.Ergonomic 320.250 DGS..................................................................................................................................................... 86
7.4.Kusovník / Stückliste / Piece list – Ergonomic 320.250 DGS....................................................................... 87
7.5.Rameno / Sägerahmen / Saw arm .............................................................................................................................. 88
7.6.Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm ................................................ 89
7.7.Rameno / Sägerahmen / Saw arm ............................................................................................................................... 90
7.8.Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm ................................................ 91
7.9.Napínání / Spannung / Tensioning............................................................................................................................. 92
7.10.Kusovník / Stückliste / Piece list – Napínání / Spannung / Tensioning ................................. 93
7.11.Vedení pásu / Sägebandführung / Belt guide ........................................................................................ 94
7.12.Kusovník / Stückliste / Piece list – Vedení pásu / Sägebandführung / Belt guide .......... 95
7.13.Vodící kostka / Führungsklotz / Guiding cube – 1 ................................................................................ 96
7.14.Vodící kostka / Führungsklotz / Guiding cube – 2 ............................................................................... 97
7.15.Konzola otočná/ Drehkonsole / Turnable consol ................................................................................. 98
7.16.Kusovník / Stückliste / Piece list – Konzola otočná / Drehkonsole / Turnable consol . 99
7.17.Svěrák / Schraubstock / Vice ............................................................................................................................100
7.18.Kusovník / Stückliste / Piece list – Svěrák / Schraubstock / Vice ..............................................101
7.19.Válec zvedací / Hebezylinder / Liftink cylinder .....................................................................................102
7.20.Kusovník / Stückliste / Piece list – Válec zvedací / Hebezylinder / Liftink cylinder .......103
7.21.Podstavec / Untersatz / Base ............................................................................................................................104
7.22.Kusovník / Stückliste / Piece list – Podstavec / Untersatz / Base...............................................105
7.23.Ovládací panel / Bedienpult / Control panel .........................................................................................106
7.24.Kusovník / Stückliste / Piece list – Ovládací panel / Bedienpult / Control panel............107
7.25.Chlazení / Kühlung / Cooling ..........................................................................................................................108
7.26.Kusovník / Stückliste / Piece list – Chlazení / Kühlung / Cooling ............................................109
7.27.Stůl / Tisch / Table....................................................................................................................................................110
7.28.Kusovník / Stückliste / Piece list – Stůl / Tisch / Table......................................................................111
7.29.Doraz / Anschlag / Stop piece..........................................................................................................................112
7.30.Kusovník / Stückliste / Piece list – Stůl / Anschlag / Stop piece................................................113
7.31.Kartáč / Bürste / Brush ..........................................................................................................................................114
7.32.Pružina / Feder / Spring .......................................................................................................................................115

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Bezpečnostní pokyny Sicherheitshinweise Safety notes
1. Safety notes

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Manual rev.: 1
Bezpečnostní pokyn
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Sicherheitshinweise
Safety notes

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Bezpečnostní pokyny Sicherheitshinweise Safety notes
The operating instructions must be read by the person, who keeps in touch with the
machine before transportation, installation, using, servicing, reparation, stocking or
removal!
The operating instructions include relevant information. The operator must familiarise
himself with the install and operation, safety notes and machine servicing, because
reliability and service life must be reached. The operating instructions must avoid risks,
which are linked to work on the machine. Before transporting and using of the
machine, please read the instructions thoroughly!
1.1. Machine determination
The band saw Ergonomic 320.250 DGS is determined for cutting and shortening of
rolled bars and drawn bars and profiles from steels, stainless steels, non-ferrous metals
and plastics with cutting angles from -45° to 60°.
Combustible materials are excepted for cutting! Any other usage and operation
outside this range are unauthorized and the manufacturer/supplier does not accept
any responsibility for any damages resulting from such misuse. The operator has full
responsibility!
The machine is equipped with safety and protective guarding for operator and
machine protection. Nevertheless, this safety and protective guarding cannot prevent
injury. Service personnel must read this chapter and comprehend it, before he starts to
work on the machine. Always keep instructions about work safety! Service
personnel must take into account other aspects of the risk, which refer to the ambient
conditions and the material.
1.2. Protective suit and personal safety
Wear tight fitting overalls! Loose fitting clothes may be caught with machine parts
and cause serious injury.
Wear protective gloves! Material cuts and saw band have sharp edges and may cause
serious injuries.
Wear protective shoes with non-skid soles! The unsuitable shoes may cause balance
loss and following injury. Falling work pieces may cause serious injuries too.
Wear protective goggles! Chips and cooling liquid may damage your eyes.
Always wear ear protections! Most of the machines emit up to 80 dB and may
damage your hearing.
Do not wear jewellery and always tie back long hair! Moving machine parts can
catch jewellery or loose hair and may cause serious injuries.
Operate the machine only when you are fit enough to work. Illnesses or injuries
diminish concentration. Avoid machine work, which may compromise the safety of you
and your colleagues!
Attention!
The operating instructions must be available at the machine!
Keep the operating instructions in good condition!
Attention!
Consider the safety signs on the machine. Do not remove or
damage them!
Attention!
Gloves you can use only at working material replacement (saw
band)! The machine and accessories must be inactive!
If the machine is running, you must not wear gloves! It is
dangerous, because some parts of the machine can catch
gloves!

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Safety notes
1.3. Safety notes for machine operator
Machine can be operated only by one person. Machine operator is responsible for
presence of other persons by the machine.
Close covers before the machine starting and check, if the covers are not damaged.
Damaged covers must be repaired or changed. Do not start the machine, if the cover is
removed! Check, if the electric cables are not damaged.
•Do not hold the material for clamping to the vice and for cutting!
•Do not operate with the buttons and the switches on the control panel, when you
have gloves!
•For machine starting take care, that there is nobody in the working area of the
machine (it means in the working area of the vice, the saw band, the saw arm etc.).
•In no circumstances touch the rotating elements.
•Work on the machine only when the machine is in good condition!
•Check at least once in a shift, if the machine is not damaged. If the machine is
damaged, you must bring the machine in order and you must inform your
superior!
•Keep your working area clean! Ensure sufficient lighting in the working area.
•Take off the spilt water or the oil from the floor and dry it. Do not touch the
cooling liquid with bare hands! Do not set the nozzle of the cooling liquid, when
the machine is started on
•Do not remove the chips from the working area of the machine, when the
machine is started on!
•Do not use the compressed air for the machine cleaning or for the chips
removing!
•Use the protective instruments for chips removal!
1.4. Safety notes for the servicing and repairs
Switch off the main switch and lock it, before you start service work! Otherwise, there is
possibility of hazardous machine starting.
Only qualified person can do the servicing and repairs. For parts changing, use only
parts, which are identical with the originals. Otherwise, there is possibility of health
hazard. Use only recommended type of the hydraulic oils and oils and lubricants!
Attention!
Machine can be operated by person older than 18 years!
Machine can be operated only person physically and mentally fit
for this activity
Keep instructions and orders about work safety!
Read the operating instructions, before you start to work on the
machine! Keep the operating instructions in good condition!
Attention!
Do not connect the machine to electricity if the covers are
removed. Do not touch the electrical equipment.
Attention!
Only a qualified professional can carry out the servicing and
repairs of the electric equipment! Take special care during the
work with electrical equipment. High voltage shock can have
fatal consequences! Always keep notes about work safety!
Otherwise, there is possibility of heavy injury!

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Bezpečnostní pokyny Sicherheitshinweise Safety notes
Do not remove or do not lock the limit switches or safety equipments! Any use of the
saw, accessories or machine parts other than that intended by the BOMAR, spol. s r.o.
company is not permitted. The guarantee on this product will be afterward lost and
BOMAR, spol. s r.o. takes no responsibility for caused damages.
1.5. Safety machine accessories
The machine is equipped with safety accessories. It protects the operator from injuries
and the machine before damage. The safety accessories are blocking accessories,
emergency switches and covers. Check once in a week the function of the safety
accessories. If the safety accessories are functionless, you must stop work and repair or
change the safety accessories.
1.5.1. Total Stop
TOTAL STOP button is used for emergency switching – off the machine in case defect
or health hazard. By pressing TOTAL STOP button is interrupted the supply of the
electrical power.
If any damages or fault appears, immediately press TOTAL STOP button! Release
the pressing button is possible by twisting of the upper part of the button.
1.5.2. Arm cover
If the cover is opened during operation, the limit switch is opened and the band saw is
stopped. The band saw is not possible start in set mode.
The band saw is stated to the operation, when the cover is closed!
1.5.3. Band saw cover
It covers the visible area of the saw band from guiding cube to the frame.
Never turn-ON saw band when cover is not mounted!
1.5.4. Saw band stretching and rupture inspection
This device checks the saw band tension and causes immediate machine stop if the
band incidentally ruptures.
Enhanced risk!
Do not come into or intervene in the cutting area. Otherwise,
there is possibility of heavy injury.

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Safety notes
The device includes a limit switch. Its adjustment is described in chapter „Servicing and
adjusting“. Check the switch carefully and periodically – adjust it if necessary.
1.6. Safety notes for the cooling
1.6.1. Instructions for first help
1. Pull off and safely remove polluted, soaked clothing.
2. For breathing, go out in the fresh air or look for first aid treatment.
3. Wash with water or use crèmes for contact with the skin.
4. Flush with water for eyes and look for first aid treatment.
5. For swallowing, drink a lot of water and induce vomiting. Look for medical help.
1.7. Umístění štítku stroje /
Maschinenschild position /
Position of machine label
Attention!
When handling cooling agents always wear hazardous
fluid-proof gloves!
Wear protective goggles!
Cooling liquid can get in contact with your eyes and may
cause permanent severe injuries

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Bezpečnostní pokyny Sicherheitshinweise Safety notes
1.8. Umístění bezpečnostních značek /
Verteilung der Sicherheitszeichen /
Position of safety symbols

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Dokumentace stroje
Dokumentation der Maschinen
Machine documentation
Sf

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Dokumentace stroje Dokumentation der Maschinen Machine documentation
2. Machine
documentation

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Dokumentace stroje Dokumentation der Maschinen Machine documentation
2.1. Technická data /
Technische Daten /
Technical data
Hmotnost stroje / Maschinengewicht / Machine weight:
•Hmotnost / Gewicht / Weight 372 kg
Rozměry stroje / Maschinengröße / Machine size :
•Délka / Länge / Lenght
•Šířka / Breite / Width
•Výška / Höhe / Height
1562 mm
900 mm
1255 mm
Elektrické vybavení / Elektrische Ausrüstung / Electical equipment:
•Napájení / Versorgungsspannun / Supply voltage
•Příkon / Gesamptschlusswert / Total Input
•Max.jištění / Max. Vorschaltsicherung / Max. Fuse
•Krytí / Schutzart / Protection
~ 3×400V, 50H z
1,7 kW
16 A
IP 54
Akustický tlak / Schalldruckpegel / Acoustic pressure:
•Ergonomic 320.250 DGS LAeqv = 59 / 65 dB1
Pohon / Atrieb / Drive:
•Typ / Typ / Type
•Výkon / Leistung / Output
•Jmenovité otáčky / Motornenndrehzahl / Nominal speed
TM 90-2/4S B5
1,1 / 1,5 kW
2800/1420 m/min
Chladící zařízení / Kühlmiteleinrichtung / Cooling equipment:
•Výkon / Leistung / Output
•Obsah nádrže / Volumen vom Kühlmittel / Capacity
0,09 kW
20 dm3
Rozměr pásu / Sägebanddimension / Band size:
2910×27(25)×0,90 mm
Řezná rychlost / Schnittgeschwindigkeit / Cutting speed:
without freq. converter: 40-80 m/min, with freq. converter: 20–120 m/min
Řezné rozsahy / Schnittbereiche / Cutting size:
0° 250 mm 320×190 mm 300×240 mm 240×240 mm
R 45° 220 mm 220×120 mm 190×240 mm 210×210 mm
L 45° 180 mm 200×100 mm 100×240 mm 160×160 mm
R 60° 130 mm 130×100 mm 130×100 mm 100×100 mm
Level of acoustic pressure:
Equivalent level of acoustic pressure A (noise) at operator position are LAeqv=59 / 65 dB for speed
40 m.min-1 / 80 m.min-1. Mentioned values are levels of emission which doesn’t have to represent safe
levels. Factors which influence real level of acoustic pressure on machine operator are: working place
characteristics, cut material, saw band. These factors have significantly influence on acoustic
pressure..

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2.2. Rozměrové schéma /
Aufstellzeichnung /
Installation diagram

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2.3. Popis /
Beschreibung /
Description

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2.4. Transportation and stocking
2.4.1. Conditions for transportation and stocking
Keep recommendations for the manufacturers for transportation and stocking! If the
recommendations are not kept, damage can occur to the machine.
•Don’t use a forklift truck for handling the machine, if you do not have license for it!
•Don’t move under suspended loads! Fault in lifting device may cause serious
injury.
•Keep a safe distance from the machine during the transport.
•Temperature of the air from -25°C to 55°C, for a short term (max. 24 hours)
temperature of the air until 70°C
•Do not expose the machine to radiation (for example microwave radiation,
ultraviolet radiation, laser radiation, x-ray radiation). Radiation can cause problems
with the machine function and deteriorating condition of the isolation.
•Take measures, to prevent damage by dampness, by vibrations and by shakes.
2.4.2. Transport and stocking preparations
Close the vice and thoroughly oil all blank surfaces.
Lower the saw frame to the lowest position.
Make sure to empty the machine of all traces of the cooling agent.
Fasten all loose parts securely to the machine.
Pack and wrap the control desk securely to avoid damage during transport.
Fix the stickers stating the minimum approximate machine weight to at least five well
visible places.
2.4.3. Transport and stocking
The machine must be secured during transportation. Screw on the palette to the floor
of the van or the trailer. Be careful that the machine is not damaged during
transportation. Store the machine only under conditions mentioned in the manual, to
avoid damage of the machine.
It is forbidden to handle the machine any other way, than it is written in this operating
instructions, the machine can be damaged.