Bomar Ergonomic 320.250 GH User manual

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

2 Manual version: 1.04 / 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:
1.04 / Mar. 2010
rev. 1
BOMAR, spol. s r.o. ©– Subject to modifications and amendments.

3

4 Manual version: 1.04 / Mar. 2010
Manual rev.: 1

5
Content
1.SAFETY NOTES ........................................................................7
1.1.Machine determination..........................................................................................................................................................8
1.2.Protective suit and personal safety.................................................................................................................................8
1.3.Safety notes for machine operator .................................................................................................................................9
1.4.Safety notes for the servicing and repairs ..................................................................................................................9
1.5.Safety notes for the servicing and repairs on hydraulic unit.......................................................................10
1.6.Safety machine accessories .............................................................................................................................................. 10
1.6.1.Total Stop..............................................................................................................................................................................................10
1.6.2.Arm cover..............................................................................................................................................................................................10
1.6.3.Band saw cover .................................................................................................................................................................................10
1.6.4.Saw band stretching and rupture inspection ...............................................................................................................11
1.7.Safety notes for the cooling .............................................................................................................................................11
1.7.1.Instructions for first help .............................................................................................................................................................11
1.8.Umístění štítku stroje / Maschinenschild position / Position of machine label.............................. 12
1.9.Umístění bezpečnostních značek / Verteilung der Sicherheitszeichen / Position of safety
symbols.......................................................................................................................................................................................... 13
2.MACHINE DOCUMENTATION................................................15
2.1.Technická data / Technische Daten / Technical data ...................................................................................... 16
2.2.Rozměrové schéma / Aufstellzeichnung / Installation diagram............................................................... 17
2.3.Popis / Beschreibung / Description.............................................................................................................................18
2.4.Transportation and stocking............................................................................................................................................ 19
2.4.1.Conditions for transportation and stocking...................................................................................................................19
2.4.2.Transport and stocking preparations..................................................................................................................................19
2.4.3.Transport and stocking ................................................................................................................................................................19
2.4.4.Transportní schéma / Transport schema / Transport scheme ........................................................................20
2.5.Activation...................................................................................................................................................................................... 21
2.5.1.Machine working conditions ...................................................................................................................................................21
2.6.Band saw unpacking and assembling .......................................................................................................................21
2.6.1.Machine installing and levelling ............................................................................................................................................21
2.6.2.Machine disposal after lifetime...............................................................................................................................................21
2.6.3.First run of the power pack.......................................................................................................................................................22
2.6.4.Filling the reservoir with hydraulic oil ................................................................................................................................22
2.6.5.Kotevní plan / Verankerungsplan / Grounding plan ................................................................................................23
2.7.Electrical connection............................................................................................................................................................. 24
2.7.1.Check the direction of the saw band..................................................................................................................................24
2.7.2.Check machine connection into electrical network.................................................................................................24
2.8.Filling of the cooling system............................................................................................................................................ 25
2.9.Check machine function .................................................................................................................................................... 25
2.10.Saw band.......................................................................................................................................................................... 25
2.10.1.Saw band size.....................................................................................................................................................................................25
2.10.2.Selection of the saw band tooth system..........................................................................................................................25
2.10.3.Saw band running-in.....................................................................................................................................................................25
2.10.4.Tables for teeth selection ...........................................................................................................................................................27
3.MACHINE CONTROL..............................................................29
3.1.Main switch .................................................................................................................................................................................30
3.2.Control panel ............................................................................................................................................................................. 30
3.2.1.Control panel – for machine without frequency converter.................................................................................30
3.2.2.Control panel – for machine with frequency converter.........................................................................................31
3.3.Cutting............................................................................................................................................................................................ 31
3.3.1.Semiautomatic cycle .....................................................................................................................................................................31
3.4.Cycle breaking........................................................................................................................................................................... 32
3.5.Band saw adjusting................................................................................................................................................................ 32
3.5.1.Cutting speed.....................................................................................................................................................................................32
3.5.2.Pressure adjusting to the cut ...................................................................................................................................................32
3.5.3.Setting of the material length .................................................................................................................................................33
3.5.4.Optimal adjusting of the guide cubes span...................................................................................................................33
3.5.5.Angular cut setting.........................................................................................................................................................................34
3.5.6.Brush adjustment.............................................................................................................................................................................35
3.6.Material insertion..................................................................................................................................................................... 36
3.6.1.Handling agent selection ...........................................................................................................................................................36
3.6.2.Insertion .................................................................................................................................................................................................36
3.6.3.Bundle material cutting...............................................................................................................................................................36
4.MACHINE SERVICE ................................................................37
4.1.Saw band dismantling and installation..................................................................................................................... 38
4.1.1.Saw band dismantling..................................................................................................................................................................38
4.1.2.Saw band installation....................................................................................................................................................................39
4.2.Saw band stretching and inspection.......................................................................................................................... 39
4.2.1.Saw band stretching......................................................................................................................................................................39
4.3.Saw band run adjustment on stretching wheel..................................................................................................39
4.3.1.Saw band run inspection............................................................................................................................................................39
4.3.2.Saw band setting .............................................................................................................................................................................40
4.4.Saw band adjusting ............................................................................................................................................................... 40
4.4.1.Hard metal guides adjustment...............................................................................................................................................40

6 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
4.4.2.Guide cube adjustment .............................................................................................................................................................. 41
4.4.3.Adjusting the limit switch of the saw band stretching.......................................................................................... 41
4.4.4.Angular stops adjustments....................................................................................................................................................... 41
4.4.5.Adjusting of the turning console securing lever........................................................................................................ 42
4.4.6.Saw frame lower position stop adjustment................................................................................................................... 43
4.4.7.Adjustment of the limit switch of saw frame lower stop point........................................................................ 43
4.4.8.Adjustment of the regulating pressure to the cut .................................................................................................... 44
4.4.9.Adjustment of a throttle valve................................................................................................................................................ 45
4.4.10.Brush adjustment............................................................................................................................................................................ 45
4.5.Cooling agents and chips disposal.............................................................................................................................. 46
4.5.1.Coolant device inspection......................................................................................................................................................... 46
4.5.2.Chips disposal.................................................................................................................................................................................... 46
4.6.Hydraulic, greases and oils ................................................................................................................................................ 47
4.6.1.Gearbox oils ........................................................................................................................................................................................ 47
4.6.2.Lubricant greases............................................................................................................................................................................ 47
4.6.3.Lubrication........................................................................................................................................................................................... 48
4.6.4.Hydraulic oils...................................................................................................................................................................................... 48
4.6.5.Hydraulic unit service ................................................................................................................................................................... 49
4.7.Machine cleaning.................................................................................................................................................................... 49
4.8.Worn pieces replacement ................................................................................................................................................. 50
4.8.1.Hard metal guides replacement............................................................................................................................................ 50
4.8.2.Saw band guiding rollers replacement ............................................................................................................................ 50
4.8.3.Round brush replacement........................................................................................................................................................ 52
4.8.4.Stretching wheel replacement............................................................................................................................................... 53
4.8.5.Driving wheel replacement...................................................................................................................................................... 55
4.8.6.Cooling pump replacement.................................................................................................................................................... 56
5.ZÁVADY / TROUBLESHOOTING ............................................59
5.1.Mechanical problems........................................................................................................................................................... 60
5.2.Electric problems..................................................................................................................................................................... 62
5.3.Hydraulic 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................................ 66
6.2.Elektrické schema /Elektroschema /Wiring diagrams – frekv. měnič / Frequenzumrichter /
Frequency convertor – 3×400 V/50 Hz, TN-C-S................................................................................................... 71
6.3.Hydraulické schéma / Hydraulikschema Hydraulic diagrams ................................................................... 76
7.VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ /
ZEICHNUNGEN FÜR BESTELLUNG DER ERSATZTEILE / DRAWING
ASSEMBLIES FOR SPARE PARTS ORDER .......................................79
7.1.Ergonomic 320.250 GH........................................................................................................................................................ 80
7.2.Kusovník / Stückliste / Piece list – Ergonomic 320.250 GH ......................................................................... 81
7.3.Rameno / Sägerahmen / Saw arm............................................................................................................................... 82
7.4.Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm................................................. 83
7.5.Rameno / Sägerahmen / Saw arm............................................................................................................................... 84
7.6.Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm................................................. 85
7.7.Konzola / Konzole / Console............................................................................................................................................ 86
7.8.Kusovník / Stückliste / Piece list – Konzola / Konzole / Console.............................................................. 87
7.9.Svěrák / Schraubstock / Vice............................................................................................................................................ 88
7.10.Kusovník / Stückliste / Piece list – Svěrák / Schraubstock / Vice ................................................. 89
7.11.Napínání / Spannung / Tensioning................................................................................................................. 90
7.12.Kusovník / Stückliste / Piece list – Napínání / Spannung / Tensioning .................................. 91
7.13.Vedení pásu / Sägebandführung / Belt guide......................................................................................... 92
7.14.Kusovník / Stückliste / Piece list – Vedení pásu / Sägebandführung / Belt guide........... 93
7.15.Vodící kostka / Führungsklotz / Guiding cube......................................................................................... 94
7.16.Kusovník / Stückliste / Piece list – Vodící kostka / Führungsklotz / Guiding cube .......... 95
7.17.Vodící kostka / Führungsklotz / Guiding cube......................................................................................... 96
7.18.Kusovník / Stückliste / Piece list – Vodící kostka / Führungsklotz / Guiding cube .......... 97
7.19.Válec zvedací / Hebezylinder / Lifting cylinder ....................................................................................... 98
7.20.Kusovník / Stückliste / Piece list – Válec zvedací / Hebezylinder / Lifting cylinder ......... 99
7.21.Podstavec / Untersatz / Base.............................................................................................................................100
7.22.Kusovník / Stückliste / Piece list – Podstavec / Untersatz / Base...............................................101
7.23.Doraz / Anschlag / Lenght Stop......................................................................................................................102
7.24.Kusovník / Stückliste / Piece list – Doraz / Anschlag / Lenght Stop .......................................103
7.25.Chlazení / Kuhlung / Cooling............................................................................................................................104
7.26.Kusovník / Stückliste / Piece list – Chlazení / Kuhlung / Cooling .............................................105
7.27.Válec / Zylinder / Roller.........................................................................................................................................106
7.28.Kartáč / Bürste / Brush ...........................................................................................................................................107

7
Bezpečnostní pokyny Sicherheitshinweise Safety notes
1. Safety notes

8 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
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 saws Ergonomic 320.250 GH and Ergonomic 320.250 GH-F 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 0° 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!
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!
Attention!
Consider the safety signs on the machine. Do not remove or
damage them!

9
Bezpečnostní pokyny Sicherheitshinweise Safety notes
1.3. Safety notes for machine operator
Machine can be operated only by one person. Machine operator is responsible for
presence of other persons by the machine.
Close covers before the machine starting and check, if the covers are not damaged.
Damaged covers must be repaired or changed. Do not start the machine, if the cover is
removed! Check, if the electric cables are not damaged.
•Do not hold the material for clamping to the vice and for cutting!
•Do not operate with the buttons and the switches on the control panel, when you
have gloves!
•For machine starting take care, that there is nobody in the working area of the
machine (it means in the working area of the vice, the saw band, the saw arm etc.).
•In no circumstances touch the rotating elements.
•Work on the machine only when the machine is in good condition!
•Check at least once in a shift, if the machine is not damaged. If the machine is
damaged, you must bring the machine in order and you must inform your
superior!
•Keep your working area clean! Ensure sufficient lighting in the working area.
•Take off the spilt water or the oil from the floor and dry it. Do not touch the
cooling liquid with bare hands! Do not set the nozzle of the cooling liquid, when
the machine is started on
•Do not remove the chips from the working area of the machine, when the
machine is started on!
•Do not use the compressed air for the machine cleaning or for the chips
removing!
•Use the protective instruments for chips removal!
1.4. Safety notes for the servicing and repairs
Switch off the main switch and lock it, before you start service work! Otherwise, there is
possibility of hazardous machine starting.
Only qualified person can do the servicing and repairs. For parts changing, use only
parts, which are identical with the originals. Otherwise, there is possibility of health
hazard. Use only recommended type of the hydraulic oils and oils and lubricants!
Attention!
Machine can be operated by person older than 18 years!
Machine can be operated only person physically and mentally fit
for this activity
Keep instructions and orders about work safety!
Read the operating instructions, before you start to work on the
machine! Keep the operating instructions in good condition!
Attention!
Do not connect the machine to electricity if the covers are
removed. Do not touch the electrical equipment.
Attention!
Only a qualified professional can carry out the servicing and
repairs of the electric equipment! Take special care during the
work with electrical equipment. High voltage shock can have
fatal consequences! Always keep notes about work safety!
Otherwise, there is possibility of heavy injury!

10 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
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 notes for the servicing and repairs on hydraulic unit
Compliance with the the principles of cleanliness is basic requirement for trouble-free
operation of hydraulic equipment. Hydraulic components are products made with high
accuracy, and any contamination leads to a reduction lifetime or even malfunction. The
consequences are very difficult to remove and expensive.
Always use clean tools. Parts and fasteners, which are part of a hydraulic circuit, never
put away the dirty surface. The best cleaning agent is crepe paper, because the fibers of
the cleaning cloths can also cause malfunction.
Protective cap from the threaded chamber remove just before the assembly of the unit.
Hoses and pipes before mounting flush with gasoline or other cleaning agent and blow
compressed air.
All fittings must be properly tightened. However, do not raw power.
1.6. 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.
1.6.1. Total Stop
TOTAL STOP button is for emergency switch–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.
1.6.2. 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!
1.6.3. Band saw cover
It covers the visible area of the saw band from guiding cube to the frame.
Enhanced risk!
Do not come into or intervene in the cutting area. Otherwise,
there is possibility of heavy injury.

11
Bezpečnostní pokyny Sicherheitshinweise Safety notes
Never turn-ON saw band when cover is not mounted!
1.6.4. Saw band stretching and rupture inspection
This device checks the saw band tension and causes immediate machine stop if the
band incidentally ruptures.
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.
1.7. Safety notes for the cooling
1.7.1. 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.
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

12 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
Bezpečnostní pokyny
Sicherheitshinweise
Safety notes
1.8. Umístění štítku stroje /
Maschinenschild position /
Position of machine label
Machine label is placed on saw band base.

13
Bezpečnostní pokyny Sicherheitshinweise Safety notes
1.9. Umístění bezpečnostních značek /
Verteilung der Sicherheitszeichen /
Position of safety symbols

14 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
Dokumentace stroje
Dokumentation der Maschinen
Machine documentation
S
Dokumentace stroje

15
aokumentace stroje Dokumentation der Maschinen Machine documentation
2. Machine
documentation

16 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
Dokumentace stroje
Dokumentation der Maschinen
Machine documentation
S
Dokumentace stroje
2.1. Technická data /
Technische Daten /
Technical data
Hmotnost stroje / Maschinengewicht / Machine weight:
Hmotnost / Gewicht / Weight 385 kg
Rozměry stroje / Maschinengröße / Machine size :
Délka / Länge / Lenght
Šířka / Breite / Width
Výška / Höhe / Height
1670 mm
1166 mm
1239 mm
Elektrické vybavení / Elektrische Ausrüstung / Electical equipment:
Napájení / Versorgungsspannun / Supply voltage
Příkon / Gesamptschlusswert / Total Input
Max.jištění / Max. Vorschaltsicherung / Max. Fuse
~ 3×400V, 50Hz, TN-C-S
2 kW
16 A
Akustický tlak / Schalldruckpegel / Acoustic pressure:
Ergonomic 320.250 GH LAeqv = 65 dB
Pohon / Atrieb / Drive:
Typ / Typ / Type
Napájení / Versorgungsspannun / Supply voltage
Výkon / Leistung / Output
Jmenovité otáčky / Motornenndrehzahl / Nominal speed
3×400 V
~ 3×400 V, 50 Hz
1,5 / 1,1 kW
2800 /1420 min-1
Hydraulické zařízení / Hydraulieinrichtung / Hydraulic equipment:
•Typ / Type / Type
•Výkon / Leistung / Output
HYTOS:SMA04-33 / HYKOM:HAH11-4,6
3 MPa / 0,25 kW
Chladící zařízení / Kühlmiteleinrichtung / Cooling equipment:
Výkon / Leistung / Output
Obsah nádrže / Volumen vom Kühlmittel / Capacity
0,09 kW
12 dm3
Rozměr pásu / Sägebanddimension / Band size:
2910×27 (25)×0,90 mm
Řezná rychlost / Schnittgeschwindigkeit / Cutting speed:
Standard: 40/80 m/min. Freq. converter: 20–120 m/min
Řezné rozsahy / Schnittbereiche / Cutting size:
0° ∅250 mm 320×170 mm 290×240 mm 240×240 mm
R 45° ∅220 mm 230×140 mm 200×230 mm 200×200 mm
R 60° ∅110 mm 130×105 mm 130×105 mm 105×105 mm
Level of acoustic pressure:
Equivalent level of acoustic pressure A (noise) at operator position are LAeqv= 65 dB. 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.

17
aokumentace stroje Dokumentation der Maschinen Machine documentation
2.2. Rozměrové schéma /
Aufstellzeichnung /
Installation diagram

18 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
Dokumentace stroje
Dokumentation der Maschinen
Machine documentation
S
Dokumentace stroje
2.3. Popis /
Beschreibung /
Description

19
aokumentace stroje Dokumentation der Maschinen Machine documentation
2.4. Transportation and stocking
2.4.1. Conditions for transportation and stocking
Keep recommendations for the manufacturers for transportation and stocking! If the
recommendations are not kept, damage can occur to the machine.
•Don’t use a forklift truck for handling the machine, if you do not have license for it!
•Don’t move under suspended loads! Fault in lifting device may cause serious
injury.
•Keep a safe distance from the machine during the transport.
•Temperature of the air from -25°C to 55°C, for a short term (max. 24 hours)
temperature of the air until 70°C
•Do not expose the machine to radiation (for example microwave radiation,
ultraviolet radiation, laser radiation, x-ray radiation). Radiation can cause problems
with the machine function and deteriorating condition of the isolation.
•Take measures, to prevent damage by dampness, by vibrations and by shakes.
2.4.2. Transport and stocking preparations
Close the vice and thoroughly oil all blank surfaces.
Lower the saw frame to the lowest position.
Make sure to empty the machine of all traces of the cooling agent.
Fasten all loose parts securely to the machine.
Pack and wrap the control desk securely to avoid damage during transport.
Fix the stickers stating the minimum approximate machine weight to at least five well
visible places.
2.4.3. Transport and stocking
The machine must be secured during transportation. Screw on the palette to the floor
of the van or the trailer. Be careful that the machine is not damaged during
transportation. Store the machine only under conditions mentioned in the manual, to
avoid damage of the machine.
It is forbidden to handle the machine any other way, than it is written in this operating
instructions, the machine can be damaged.

20 Manual version: 1.04 / Mar. 2010
Manual rev.: 1
Dokumentace stroje
Dokumentation der Maschinen
Machine documentation
S
Dokumentace stroje
2.4.4. Transportní schéma /
Transport schema /
Transport scheme