Bomar Practix Automatic Series User manual

Series Practix Automatic
Practix 285.230 GA
Operating Instructions for Band Saw
Before transporting and using the machine,
please read the instructions thoroughly!
Seriové číslo / Serien Nummer / Serial Number ___________________

2 Manual version: 1.00/ May. 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
Phone: +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:
1.00 / May 2010
rev. 1
BOMAR, spol. s r.o. ©–Sub
j
ect to modifications and amendments.

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Content
1. SAFETY NOTES ........................................................................7
1.1. Band saw using....................................................................................................................................................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 button...........................................................................................................................................11
1.5.2. Saw arm cover .......................................................................................................................................................11
1.5.3. Saw band cover ....................................................................................................................................................11
1.5.4. Saw band stretching and rupture inspection ...................................................................................12
1.5.5. Protection grate for the operator station.............................................................................................12
1.6. Safety notes for cooling system .............................................................................................................12
1.6.1. Instructions for first help .................................................................................................................................12
1.7. Umístění štítku stroje / Maschinenschild position / Position of machine label .......13
1.8. Umístění bezpečnostních značek / Verteilung der Sicherheitszeichen / Position of
safety symbols ...................................................................................................................................................14
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
2.5. Transportní schéma / Transportschema / Transport diagram..........................................21
2.6. Activation..............................................................................................................................................................22
2.6.1. Machine working conditions .......................................................................................................................22
2.6.2. Band saw unpacking and assembling ...................................................................................................22
2.6.3. Machine installing and levelling ................................................................................................................22
2.6.4. Machine disposal after lifetime...................................................................................................................22
2.7. Kotevní plan / Verankerungsplan / Grounding plan...............................................................23
2.8. Electrical connection.....................................................................................................................................24
2.8.1. Check the direction of the saw band......................................................................................................24
2.9. Filling of the cooling system.....................................................................................................................24
2.10. Check machine functions................................................................................................................25
2.11. Saw band...................................................................................................................................................25
2.11.1. Saw band size .................................................................................................................................................25
2.11.2. Selection of the saw band tooth system.......................................................................................25
2.11.3. Saw band running-in .................................................................................................................................26
2.11.4. Tables for teeth selection........................................................................................................................27
3. MACHINE CONTROL..............................................................29
3.1. Machine start......................................................................................................................................................31
3.2. The Control panel............................................................................................................................................32
3.3. Selection of the machine operation mode.....................................................................................34
3.3.1. Service mode..........................................................................................................................................................34
3.3.2. Manual mode.........................................................................................................................................................35
3.3.3. Automatic mode..................................................................................................................................................36
3.4. Working cycle interruption........................................................................................................................38
3.5. Error messages ..................................................................................................................................................38
3.6. Selection of saw band speed...................................................................................................................38
3.7. Cutting angle setting ....................................................................................................................................39
3.8. Guiding cube setting.....................................................................................................................................39
3.9. Inserting the material....................................................................................................................................40
3.9.1. Inserting.....................................................................................................................................................................40
3.9.2. Clamping material to the vice.....................................................................................................................40
3.9.3. Cutting of the bundle.......................................................................................................................................40
4. MACHINE SERVICE ................................................................41
4.1. Saw band dismantling..................................................................................................................................43
4.2. Saw band installation....................................................................................................................................43
4.3. Saw band stretching and inspection..................................................................................................43
4.3.1. Saw band stretching..........................................................................................................................................43
4.3.2. Saw band inspection.........................................................................................................................................44

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4.4. Cooling agents and chips disposal ......................................................................................................44
4.4.1. Coolant device inspection.............................................................................................................................44
4.4.2. Chips disposal........................................................................................................................................................45
4.5. Greases and oils................................................................................................................................................45
4.5.1. Gearbox oils.............................................................................................................................................................45
4.5.2. Lubricant greases ................................................................................................................................................46
4.6. Hydraulic oil level check and Hydraulic oils....................................................................................46
4.6.1. Hydraulic oils ..........................................................................................................................................................46
4.6.2. Hydraulic oil level check..................................................................................................................................47
4.7. Machine cleaning............................................................................................................................................47
5. TROUBLESHOOTING .............................................................49
5.1. Mechanical defects.........................................................................................................................................51
5.2. Electrical defects...............................................................................................................................................53
6. SCHÉMATA / SCHEMAS / SCHEMATICS ...............................55
6.1. Elektrické schema / Elektroschema / Wiring diagrams – 3×400 V, TN-C-S .................56
6.2. Elektrické schema / Elektroschema / Wiring diagrams – 3×230 V, TN-C......................69
6.3. Elektrické schema / Elektroschema / Wiring diagrams – 3×400 V, TN-C......................82
6.4. Hydraulické schéma / Hydraulikschema / Hydraulic diagram..........................................96
7. VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ /
ZEICHNUNGEN FÜR BESTELLUNG DER ERSATZTEILE / DRAWING
ASSEMBLIES FOR SPARE PARTS ORDER .......................................99
7.1. Pila / Säge / Saw............................................................................................................................................100
7.2. Kusovník / Stückliste / Piece list – Pila / Säge / Saw..............................................................101
7.3. Skluz / Rutsch / Glide..................................................................................................................................102
7.4. Kusovník / Stückliste / Piece list – Skluz / Rutsch / Glide....................................................103
7.5. Podstavec / Säge / Saw.............................................................................................................................104
7.6. Kusovník / Stückliste / Piece list – Podstavec / Säge / Saw...............................................105
7.7. Konzola / Konsole / Console..................................................................................................................106
7.8. Kusovník / Stückliste / Piece list – Konzola / Konsole / Console....................................107
7.9. Válec svěráku / Schraubstockzylinder / Vice cylinder............................................................108
7.10. Kusovník / Stückliste / Piece list – Válec svěráku / Schraubstockzylinder /
Vice cyl.................................................................................................................................................................109
7.11. Svěrák / Schraubstock / Vice ......................................................................................................110
7.12. Kusovník / Stückliste / Piece list – Svěrák / Schraubstock / Vice.........................111
7.13. Rameno / Sägerahmen / Saw arm .........................................................................................112
7.14. Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm............113
7.15. Rameno / Sägerahmen / Saw arm .........................................................................................114
7.16. Kusovník / Stückliste / Piece list – Rameno / Sägerahmen / Saw arm............115
7.17. Napínání / Spannung / Tension...............................................................................................116
7.18. Kusovník / Stückliste / Piece list – Napínání / Spannung / Tension.................117
7.19. Podavač / Vorschub / Feeder.....................................................................................................118
7.20. Kusovník / Stückliste / Piece list – Podavač / Vorschub / Feeder.......................119
7.21. Podavač / Vorschub / Feeder.....................................................................................................120
7.22. Kusovník / Stückliste / Piece list – Podavač / Vorschub / Feeder 2...................121
7.23. Váleček / Rolle / Roller....................................................................................................................122
7.24. Kusovník / Stückliste / Piece list – Váleček / Rolle / Roller......................................123
7.25. Váleček / Rolle / Roller 2................................................................................................................124
7.26. Kusovník / Stückliste / Piece list – Váleček / Rolle / Roller 2..................................125
7.27. Váleček vertikální / Rolle vert. / Vert. Roller........................................................................126
7.28. Kusovník / Stückliste / Piece list – Váleček vertikální / Rolle vert. / Vert. Roller127

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Bezpečnostní pokyny Sicherheitshinweise Safety notes
1. 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 must avoid risks, which are linked to work on the machine.
Before transporting and using of the machine, please read the instructions thoroughly!
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.
1.1. Band saw using
The band saw Practix 285.230 GA is used 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° in manual mode and angles from 0° to 45° in automatic
mode.
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!

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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, if 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! When repair
machine remove power cord from the outlet. 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.
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.
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!
Do not connect the machine to electricity if the covers are
removed. Do not touch the electrical equipment.

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Bezpečnostní pokyny Sicherheitshinweise Safety notes
The guarantee on this product will be afterward lost and BOMAR, spol. s r.o. takes no
responsibility for caused damages!
Do not start the machine, if the covers are not on their places!
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 button
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.
Release the pressing button is possible by twisting of the upper part of the button.
1.5.2. Saw arm cover
The band saw is stated to the operation, when the cover is closed!
1.5.3. Saw band cover
This protective cover envelops the saw band in the area from guiding cube to the arm.
Never switch the saw band on if this cover is not mounted!
Enhanced risk!
Do not come into or intervene in the cutting area.
Otherwise, there is possibility of heavy injury.
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.
If any damages or fault appears, immediately press TOTAL
STOP button!

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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.
The device includes a limit switch. Check the switch carefully and periodically – adjust it
if necessary.
1.5.5. Protection grate for the operator station
The protection grate protests the operators from catching or pushing from the moving
parts of the machine or the material.
Do not use the saw without protection grate.
1.6. Safety notes for cooling system
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.
Attention!
Keep notes about work safety for handling cooling liquid!
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
1.7. Umístění štítku stroje /
Maschinenschild position /
Position of machine label
Machine label is located on the pedestal in the hydraulic aggregate access area.

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1.8. Umístění bezpečnostních značek /
Verteilung der Sicherheitszeichen /
Position of safety symbols

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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 580 kg
Rozměry stroje / Maschinengröße / Machine size
•Délka / Länge / Lenght
•Šířka / Breite / Width
•Výška / Höhe / Height
2250 mm
1600 mm
1350 mm
Akustický tlak / Schalldruckpegel / Acoustic pressure:
•Practix 285.230 GA LAeqv= 71,2 dB / 73,6 dB – 35 m.min-1 / 72 m.min-1
Elektrické zařízení / Elektrische Ausrüstung / Electrical equipment:
•Napájení / Versorgungsspannun / Supply voltage
•Příkon / Gesamptschlusswert / Total Input
•Max. jištění / Max. Vorschaltsicherung / Max. Fuse
•Krytí / Schutzart / Protection
~ 3×400 V, 50 Hz TN-C-S/TN-C,
~ 3×230 V/50 Hz TN-C
2 kW
16 A
IP 54
Motor pohonu pily / Antrieb / Sawband drive:
•Typ / Typ / Type
•Napájení / Versorgungsspannun / Supply voltage
•Výkon / Leistung / Output
•Jmenovité otáčky / Motornenndrehzahl / Nominal speed
MSD90L-8/4
~3×400 V, 50 Hz
0,7/1,1 kW
1420/690 min-1
Hydraulické zařízení / Hydraulische Geräte / Hydraulic equipment:
•Typ / Typ / Type
•Výkon / Leistung / Output
•Obsah nádrže / Volumen vom Kühlmittel / Capacity
870-1395 (92.001.019)
3 MPa / 0,55 kW
30 l
Chladící zařízení / Kühlmiteleinrichtung / Cooling equipment:
•Typ / Typ / Type
•Napájení / Versorgungsspannun / Supply voltage
•Obsah nádrže / Volumen vom Kühlmittel / Capacity
91.020.019
~ 1×230V, 50Hz
20 l
Rozměr pásu / Sägebanddimension / Band size:
2720×27×0,90 mm
Řezná rychlost / Schnittgeschwindigkeit / Cutting speed:
35/72 m.min-1
Řezné rozsahy / Schnittbereiche / Cutting size:
0° Ø225 mm 280×70 mm 245×225 mm 225×225 mm
R 45° Ø180 mm 180×125 mm 200×170 mm 170×170 mm
R 60° Ø120 mm 115×95 mm 95×95 mm 95×95 mm
Hladina akustického tlaku – practix 280.230 G:
Equivalent level of acoustic pressure A (noise) at operator position are LAeqv = 71,2 dB / 73,6 dB for 35 m.min-1 / 72
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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Dokumentace stroje Dokumentation der Maschinen Machine documentation
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.
•Do not use a forklift truck for handling the machine, if you do not have licence for
it!
•Do not move under suspended loads! Fault in lifting device may cause serious
injury.
•Keep a safe distance from the machine during the transport.
Conditions for transportation and stocking:
•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, ultra-
violet 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.
•The machine has to be screwed to a pallet for the transport!
2.4.3. Transport and stocking
Handle the machine only with the hand pallet truck or the forklift truck! If the machine
is equipped with the shackles in the pedestal, you can use the suspension cable and
the crane.
Make sure that the hand pallet truck; the forklift truck or the crane had sufficient
capacity.
Make sure that the van or the trailer had sufficient capacity.
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 (for example by, lifting by the saw
frame of the band saw), than it is written in this operating instructions, the machine can
be damaged!