Bomar Ergonomic Series User manual

Series Ergonomic
Ergonomic 340.278 DG
Operating instructions
Before transporting and using the machine,
please read the instructions thoroughly!
Seriové číslo / Serien Nummer / Serial Number ___________________

2

VersionNo. 00.00.00
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:
1.03/ May 2016
rev. 1
BOMAR, spol. s r.o.
©
–
Subject to modifications and amendments.

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Manual rev.: 1
EC Declaration of Conformity
1) 2) We: BOMAR, spol. s r.o.
Těžební 1236/1
627 00 Brno, Czech Republic
Id. No: 48908827
declare herewith
that the following designated device based on its conception and construction as well as the design launched by us
meets the relevant basic safety requirements of the decrees of the government.
This statement applies exclusively to the machine device in conditions in which it was brought to the market. It does
not apply to parts subsequently added by the end user or to modifications performed subsequently by the end
user.
In the event of any device modification not approved by us this declaration shall lose its validity
Name: Band Saw
Type : Ergonomic 340.275 DG
Serial number:
Manufacturer BOMAR, spol. s r.o., Těžební 1236/1, 627 00 Brno
Product data
Determination: for cross dividing and cutting of rolled and towed bars and profiles made of steel, stainless
steel, non-ferrous metals and plastics
Description: Stand, table, cutting unit with the saw band and drive, clamping device, cooling
system, el. switch board with control panel.
Pneumatic NO YES Hydraulic NO YES Control system NO YES
Technical data: Cutting rate 20-120 m.min-1
Cutting angle -45°- to -60°
Total dimensions in mm (l×w×h) 1960x1570x1770 mm
Supply voltage 400 V TN-C-S, 400 V TN-C, 230 V TN-C
Total power requirement 1,7 kW
Weight 372 kg
Documentation:
Technical documentation for this machine device was elaborated in compliance with Government regulation no. 176/2008,
Annex 7, part A.
The device meets relevant requirements of the given directives: 2006/42/EC
2004/108/EC
The applied harmonized standards, National standards and technical specifications:
ČSN EN ISO 12100:2011 ČSN EN 13898+A1:2009 ČSN EN ISO 13857:2008
ČSN EN 60204 -1 ed.2+A1:2009
ČSN EN 55011 ed.3+A1:2011 ČSN EN 61000-6-2 ed.3:2006 ČSN EN 61000-6-4 ed.2+A1:2011
The product is safe on condition of the common and determined usage.
The conformity judging was performed according to §12, par. 3, let. a), of the Law no. 22/1997 Coll. as amended.
The declaration of conformity was carried out in the cooperation with the 3) TÜV SÜD Czech s.r.o, Novodvorská 994, 142 21
Prague 4 – Czech Republic, Identification number: 63987121 - Inspection body no. 4002.
The inspection certificate no 07.801.283 was issued
Brno,.31.08..2015 Alfred Pichlmann, Managing Director
Point of issue, datum Name and function of the responsible
subject, signature
1) Name, address and identification number of the subject issuing the conformity declaration (producer of importer)
2) Person authorized to complete the technical documentation
3) The authorized or accredited body co-operating on the conformity judging

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!
If the equipment is installed without safety equipment offered by BOMAR, spol. s ro or its agents and used by the customer (or
buyer) then EC declaration loses validity.
EC Declaration of conformity is valid only if customer (buyer) installed the BOMAR safety equipment with the machine or with
some other with equivalent safety device in accordance with current applicable regulations and standards.
All machine elements and components that were built into the device by BOMAR, spol. s ro have been declared "identical" to a
safety device, as offered by BOMAR, spol. s ro or its agents.

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Content
1. BEZPEČNOSTNÍ POKYNY / SAFETY NOTES /
SICHERHEITSHINWEISE ................................................................ 11
1.1. Machine determination................................................................................................................... 13
1.2. Protective clothing and personal safety ...................................................................................... 13
1.3. Safety notes for machine operator .............................................................................................. 15
1.4. Safety notes for the servicing and repairs .................................................................................. 17
1.4.1. Safety notes for the servicing and repairs on hydraulic unit ................................... 17
1.5. Safety notes for the cooling........................................................................................................... 17
1.5.1. Instructions for first aid .................................................................................................... 17
1.6. Safety machine accessories ........................................................................................................... 19
1.6.1. Total Stop ........................................................................................................................... 19
1.6.2. Arm cover ........................................................................................................................... 19
1.6.3. Saw band covers .............................................................................................................. 20
1.6.4. Saw band stretching and rupture inspection ............................................................. 21
1.7. Umístění štítku stroje / Maschinenschild position / Position of the machine label .......... 22
1.8. Umístění bezpečnostních značek / Verteilung der Sicherheitszeichen / Position of safety
symbols.............................................................................................................................................. 23
2. DOKUMENTACE STROJE / MACHINE DOCUMENTATION /
DOKUMENTATION DER MASCHINE ............................................. 25
2.1. Technická data / Technische Daten / Technical data ............................................................. 27
2.2. Rozměrové schéma / Aufstellzeichnung / Installation diagram ........................................... 28
2.3. Popis / Beschreibung / Description ............................................................................................ 30
2.4. Transportation and stocking ......................................................................................................... 32
2.4.1. Conditions for transportation and stocking ............................................................... 32
2.4.2. Transport and stocking preparations .......................................................................... 32
2.4.3. Transport and stocking ................................................................................................... 32
2.4.4. Transportní schéma / Transport schema / Transport diagram ........................... 33
2.5. Activation .......................................................................................................................................... 34
2.5.1. Machine working conditions ......................................................................................... 34
2.6. Band saw unpacking and assembling ........................................................................................ 34
2.6.1. Installation of the length stop for the material length setting ............................... 34
2.6.2. Attachment of the cooling liquid tub .......................................................................... 36
2.6.3. Assembly of the hand wheel ......................................................................................... 36
2.6.4. Machine installing and leveling ..................................................................................... 38
2.6.5. Machine disposal after lifetime ..................................................................................... 38
2.6.6. Kotevní plan / Verankerungsplan / Grounding plan................................................ 39
2.7. Electrical connection ....................................................................................................................... 40
2.7.1. Check the direction of the saw band .......................................................................... 40
2.7.2. Inspection of the connection to the electrical network ............................................41
2.8. Filling of the cooling system .......................................................................................................... 41
2.9. Machine functions check ................................................................................................................ 41
2.10. Saw band ................................................................................................................................. 42
2.10.1. Saw band size ............................................................................................................. 42
2.10.2. Selection of the saw band tooth system ............................................................... 42
2.10.3. Saw band running-in ................................................................................................. 42
2.11. Table for teeth selection ................................................................................................................ 44
3. OVLÁDÁNÍ STROJE / MACHINE CONTROL / BEDIENUNG DER
MASCHINE .................................................................................. 45
3.1. Starting the band saw and switching on the safety circuits .................................................. 47
3.2. Control elements ............................................................................................................................. 48
3.3. Machine control .............................................................................................................................. 50
3.3.1. Cutting ................................................................................................................................ 50
3.3.2. Setting of the material length ....................................................................................... 52
3.3.3. Setting of the cutting angle ........................................................................................... 53
3.3.4. Setting of the optimal span of the guiding cubes .................................................... 56
3.3.5. Cutting speed adjustment.............................................................................................. 56

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3.3.6. Speed adjustment of the arm lowering ...................................................................... 56
3.3.7. Setting the type of cooling ............................................................................................ 58
3.4. Material insertion ............................................................................................................................ 59
3.4.1. Selecting means of manipulation ................................................................................. 59
3.4.2. Insertion ............................................................................................................................. 59
3.4.3. Bundle material cutting .................................................................................................. 59
4. ÚDRŽBA STROJE / MACHINE MAINTENANCE / WARTUNG .. 60
4.1. Saw band dismantling .................................................................................................................... 62
4.2. Saw band installation ..................................................................................................................... 64
4.3. Saw band stretching and inspection .......................................................................................... 66
4.3.1. Saw band stretching ........................................................................................................ 67
4.3.2. Saw band inspection ....................................................................................................... 67
4.4. Adjustment ....................................................................................................................................... 68
4.4.1. Saw band run adjustment .............................................................................................. 68
4.4.2. Hard metal guides adjustment on the machine ....................................................... 68
4.4.3. Guide cube adjustment .................................................................................................. 69
4.4.4. Brush adjustment ............................................................................................................. 69
4.4.5. Adjusting the limit switch of the saw band stretching .............................................. 71
4.4.6. Saw frame lower position stop adjustment ............................................................... 72
4.4.7. Adjustment of the limit switch of saw frame lower stop ......................................... 72
4.5. Cooling agents and chip disposal ................................................................................................73
4.5.1. Coolant inspection ........................................................................................................... 73
4.5.2. Cooling liquid preparation ............................................................................................. 74
4.5.3. Chips disposal ................................................................................................................... 74
4.6. Gearbox oils and greases ...............................................................................................................76
4.6.1. Gearbox oils ...................................................................................................................... 76
4.6.2. Lubrication greases ......................................................................................................... 77
4.6.3. Lubrication ......................................................................................................................... 77
4.6.4. Hydraulic oils ..................................................................................................................... 78
4.7. Machine cleaning .............................................................................................................................78
4.8. Worn pieces replacement ..............................................................................................................79
4.8.1. Hard metal guides replacement ................................................................................... 79
4.8.2. Saw band guiding rollers replacement ....................................................................... 80
4.8.3. Worn brush replacement ............................................................................................... 82
4.8.4. Stretching wheel replacement ...................................................................................... 83
4.8.5. Driving wheel replacement ............................................................................................ 85
4.8.6. Cooling pump replacement .......................................................................................... 86
5. ZÁVADY / TROUBLESHOOTING / STÖRUNGEN ................... 89
5.1. Mechanical problems ...................................................................................................................... 91
5.2. Electrical problems .......................................................................................................................... 93
5.2.1. Hydraulic problems ......................................................................................................... 94
6. SCHÉMATA / SCHEMATA / SCHEMATICS ........................... 98
6.1. Elektrická schémata / Elektroschemas / Wiring diagrams –3×400 V + PE, 50Hz –frekv.
měnič / Frequenzumrichter / frequency convertor ............................................................... 100
6.2. Elektrické schéma /Elektroschema /Wiring diagrams – – 2×230 V + PE, 50Hz –frekv.
měnič / Frequenzumrichter / frequency convertor ................................................................ 113
6.3. Hydraulické schéma Hydraulisches Schéma Hydraulic diagram ......................................... 128
7. VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ /
ZEICHNUNGEN FÜR BESTELLUNG DER ERSATZTEILE / DRAWING
ASSEMBLIES FOR SPARE PARTS ORDER ..................................... 132
7.1. Ergonomic 340.278 DG ................................................................................................................ 134
7.2. Kusovník / Piece list / Stückliste - Ergonomic 340.278 DG ................................................... 135
7.3. Ergonomic 340.278 DG ................................................................................................................ 136
7.4. Kusovník / Piece list / Stückliste - Ergonomic 340.278 DG ................................................... 137
7.5. Chlazení / Cooling / Kühlung ...................................................................................................... 138
7.6. Kusovník / Piece list / Stückliste - Chlazení / Cooling / Kühlung ........................................ 139
7.7. Ovladací panel / Control panel / Bedienpult ........................................................................... 140
7.8. Kusovník / Piece list / Stückliste - Ovladací panel / Control panel / Bedienpult ..............141

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7.9. Doraz / Stop piece / Anschlag .................................................................................................... 142
7.10. Kusovník / Piece list / Stückliste - Doraz / Stop piece / Anschlag ............................. 143
7.11. Podstavec / Base / Untersatz ...................................................................................................... 144
7.12. Kusovník / Piece list / Stückliste - Podstavec / Base / Untersatz ............................... 145
7.13. Konzola otočná / Turnable consol / Drehkonsole ........................................................ 146
7.14. Kusovník / Piece list / Stückliste - Konzola otočná / Turnable consol / Drehkonsole147
7.15. Kartáč / Brush / Bürste ........................................................................................................ 149
7.16. Válec zvedací / Lifting cylinder / Hebezylinder ............................................................. 150
7.17. Kusovník / Piece list / Stückliste - Válec zvedací / Lifting cylinder / Hebezylinder 151
7.18. Stůl / Table / Tisch ................................................................................................................ 152
7.19. Kusovník / Piece list / Stückliste - Stůl / Table / Tisch .................................................. 153
7.20. Svěrák / Vice / Schraubstock ............................................................................................. 154
7.21. Kusovník / Piece list / Stückliste - Svěrák / Vice / Schraubstock ................................ 155
7.22. Doraz / Stop piece / Anschlag .......................................................................................... 156
7.23. Kusovník / Piece list / Stückliste - Doraz / Stop piece / Anschlag ............................. 157
7.24. Rameno / Saw arm / Sägerahmen ................................................................................... 158
7.25. Kusovník / Piece list / Stückliste - Rameno / Saw arm / Sägerahmen ...................... 159
7.26. Rameno / Saw arm / Sägerahmen ................................................................................... 161
7.27. Kusovník / Piece list / Stückliste - Rameno / Saw arm / Sägerahmen ...................... 162
7.28. Pohon / Drive / Antrieb ...................................................................................................... 163
7.29. Pohon / Drive / Antrieb ...................................................................................................... 164
7.30. Vedení pásu / Belt guide / Sägebandführung ............................................................... 165
7.31. Kusovník / Piece list / Stückliste - Vedení pásu / Belt guide / Sägebandführung . 166
7.32. Kostka vodící / Lead cube / Führungsklotz .................................................................... 167
7.33. Kostka vodící / Lead cube / Führungsklotz .................................................................... 168
7.34. Napínání / Tensioning / Spannung .................................................................................. 169
7.35. Kusovník / Piece list / Stückliste - Napínání / Tensioning / Spannung ..................... 170

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Bezpečnostní pokyny Sicherheitshinweise
Safety notes
1. Bezpečnostní pokyny /
Safety notes /
Sicherheitshinweise

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Bezpečnostní pokyny Sicherheitshinweise
Safety notes
The operating instructions must be read by any person, who gets in touch with the
machine during transportation, installation, using, servicing, reparation, stocking or
removal!
The operating instructions include relevant information. The operator must
familiarize himself with the installation and operation, safety notes and machine
servicing, to reach maximum reliability and lifespan. The operating instructions
serve to avoid risks, which are linked with work on the machine. Before transporting
and using the machine, please read the instructions thoroughly!
1.1. Machine determination
The band saw Ergonomic 340.278 DG is determined for cutting and shortening of
rolled bars and drawn bars as well as profiles from steels, stainless steels, non-
ferrous metals and plastics with cutting angles -45° to 60°.
Combustible materials are excluded from 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 measures for both the operator
and the machine to be protected. Nevertheless, these measures cannot prevent all
injuries. All personnel must read this chapter and understand it, before they start to
work on the machine. Always follow the instructions about work safety! The
personnel must take into account other aspects of the risk, which include the
conditions of the working place and the material.
1.2. Protective clothing and personal safety
Wear fitting clothes! Loosely fitting clothes may be caught in the moving machine
parts and cause serious injuries.
Wear protective gloves! Material cuts and saw band have sharp edges and may
cause injuries.
Wear protective shoes with non-skid soles! Unsuitable shoes may cause balance
loss and following injury. Falling pieces may cause serious injuries too.
Wear protective goggles! Chips and cooling liquid may damage your eyes.
Attention!
The operating instructions must be available at the machine
position! Keep the operating instructions in a good condition!
Attention!
Gloves can be worn only when manipulating with the
material or replacing parts! The machine and its
accessories must be inactive!
If the machine is running, you must not wear gloves! There
is a higher risk of getting caught in the moving machinery!

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Always wear ear protection! 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.

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Bezpečnostní pokyny Sicherheitshinweise
Safety notes
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!
1.3. Safety notes for machine operator
Machine can be operated only by one person. Machine operator is responsible for
other people present near the machine.
Close covers before starting the machine and check, if the covers are not damaged.
Damaged covers must be repaired or changed immediately. 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 in the vice and when cutting!
 Do not operate the buttons and 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 (the working area of the vice, the saw band, the saw arm etc.).
 Under 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 to a halt and 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 running.
 Do not remove the chips from the working area of the machine, when the
machine is running!
Attention!
Mind the safety signs on the machine. Do not remove or
damage them!
Attention!
Machine can be operated by person older than 18 years!
Machine can be operated only by a person physically and
mentally fit for this activity
Follow the 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 or
wiring.

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 Do not use compressed air for the machine cleaning or for the chip removal!
 Use the protective instruments for chip removal!

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Safety notes
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 a possibility of starting the machine accidentally.
Only qualified person can do the servicing and repairs. For parts replacement, use
only those, which are identical with the originals. Otherwise, there is possibility of
health hazard. Use only recommended types of hydraulic oils, oils and lubricants!
Do not remove lock the limit switches or safety equipment! 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 lost afterward and
BOMAR, spol. s r.o. takes no responsibility for damage caused.
1.4.1. Safety notes for the servicing and repairs on hydraulic unit
Compliance with the principles of cleanness is a basic requirement for trouble-free
operation of hydraulic equipment. Hydraulic components are products made with
high precision, and any contamination leads to a reduction of lifetime and even
malfunction. The consequences are very difficult and expensive to remove.
Always use clean tools. Never put parts and fasteners which are a part of the
hydraulic circuit on a dirty surface. The best cleaning agent is crepe paper. The
fibers of the cleaning cloths can also cause malfunction.
Remove the protective caps from the threaded chamber just before the assembly
of the unit.
Flush hoses and pipes before mounting with gasoline or other cleaning agent and
blow compressed air through them.
All fittings must be properly tightened. However, do not use brute strength.
1.5. Safety notes for the cooling
1.5.1. Instructions for first aid
1. Pull off and safely remove polluted, soaked clothing.
2. If inhaled, go out on fresh air or look for first aid treatment.
Attention!
Only a qualified professional can carry out the servicing
and repairs of the electrical equipment! Take special care
during the work with electrical equipment. High voltage
shock can have fatal consequences! Always follow the work
safety instructions! Otherwise, there is possibility of heavy
injury!
Attention!
 When handling the coolant always keep to the work
safety directives and instructions of the manufacturer.
 When handling cooling agents always wear safety
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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3. Wash with water and eventually treat with crème any points of contact with the
skin.
4. Flush your eyes with water and seek out a doctor.
5. If swallowed, drink a lot of water and induce vomiting. Look for medical help

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Safety notes
1.6. Safety machine accessories
The machine is equipped with safety accessories. They protect the operator from
injuries and the machine from damage. The safety accessories are blocking
accessories, emergency switches and covers. Check the function of the safety
accessories once a week. If the safety accessories are not fulfilling their function,
stop your work and repair or change the safety accessories.
1.6.1. Total Stop
TOTAL STOP button is used for emergency switching – off of the machine in a case
of defect or health hazard. By pressing the TOTAL STOP button the supply of the
electrical power is interrupted.
If any damages or fault appear, immediately press the TOTAL STOP button!
Release of the pressed button is possible by turning the upper part of the button.
1.6.2. Arm cover
Enhanced risk!
Do not come into or intervene in the cutting area.
Otherwise, there is a possibility of heavy injury.

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If the cover is opened during operation, the limit switch is opened and the band
saw is stopped. The machine cannot be run with the arm open even in the service
mode.
Make sure the arm cover is closed before starting the machine!
1.6.3. Saw band covers
These three covers cover the band of the saw
- from the moveable guiding cube to the arm