CARIF 450 BA User manual

WARNING:
Before starting the machine, please read these instructions completely.
CARIF SAWING MACHINES S.R.L.
Via Tre Salti, 1
I-20029 Turbigo (Ml)
Italy
[phone]
[phone]
[e-mail]
www.carif.it
AUTOMATIC HYDRAULIC BAND SAWING MACHINE
“CARIF 450 BA CNC”
Manufacturer:
Address:
Tel :
Fax:
Email:
Web:
Type of machine:
CARIF 450 BA
Instruction manual

450 BA

450 BA
1. Introduction
1.1 General safety instruction
1.2 Safety device
1.3 Safety symbols
2. Machine description
2.1 Main characteristics
2.2 Technical data
3. Installation
3.1 Storage and transportation
3.2 Installation plan
3.3 How to set up the carriage cylinder
3.4 How to set up the standard roller unit for bar support l=1m and how to
set up the optional roller unit for bar support
3.5 Electrical connection
3.6 Coolant filling
3.7 Expulsion of air from the carriage cylinder
4. Operation
4.1 Keyboard description
4.2 Semiautomatic mode
4.3 Automatic mode
4.3.1 Programs list
4.3.2 Sub-programs
4.4 Cycle pause
4.5 Flanging
4.6 Set of bars
4.7 Blade stress
4.8 Machine parameters
4.9 Hydraulic pump
4.10 Type of blades
4.11 How to position the material in the vice
4.12 Cutting speed
5. Malfuctioning
5.1 Emergencies and error messages
5.2 Sawing frame (bow) calibration
6. Maintenance
6.1 Blade replacement
6.1.1 Blade tension
6.2 Scheduled maintenance
6.3 Spare parts
7. Optional
7.1 Roller units
7.2 Minimal air/oil lubrication system
7.3 Digital angle
7.4 Laser device
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Index

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450 BA
1. Introduction
1.1 General safety instruction
1.2 Safety Devices
The instruction manual is a very important
item of your equipment. It states all the
rules and guides to eciently operate the
machine.
It is kindly suggested to familiarize with
the main functions reading carefully this
manual.
CARIF machines are equipped with safety
devices.
It is however important that the operator
runs the machine carefully to avoid any
dangers.
The machine is equipped with the following
safety devices.
All the instruction in this manual must be
followed in any moments during the usage
and maintenance of the machine.
CARIF reserves itself from eventual bad
situations caused to people or damages
caused to the machine without following
this instruction manual.
Each person who will installing, operating,
servicing or repairing at the customer’s
facility must have read and understood the
instruction manual.
These must be substituted when not
working correctly.
EMERGENCY STOP switch
Electrical overload protection
Electrical locking
Saw blade covers
Operating the machine without using the provided safety devices, may lead to
severe injuries. Operate the machine only if all safety are at their places working
correctly.
All functions of the band saw are stopped
immediately.
Motors are turn o in case of overload.
If bow carter is open the saw blade will
stop.
The saw blade is cover completely, only the
cutting area accessible.
SAFETY DEVICE FUNCTION

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450 BA
In spite of all safety devices all the machines are potentially dangerous.
Further dangers must be carefully controlled.
• The clamping may cause serious injuries if obstructed on their way
• The saw blade may cause serious injuries if obstructed during the cutting
• The saw frame may cause serious injuries during its down stroke
• The saw band may cause injuries during replacement
To reduce to minimum this risk please read the following general rules:
• Only authorized personnel should operate the installation.
• Machines repairs or any changes to the machine or installation without specific
instruction are prohibited.
• The operator must take care that nobody gets near to the moving parts of the
machine during cutting.
• Only when machine is turned o should any adjustments or set-up operation be
performed.
• Wearing gloves when replacing the saw band.
• Wearing gloves when cleaning the machine especially if using air/water flushing
guns.
• If maintenance work or repairs need to be performed turn o the main switch.
Before opening any Hydraulic or Electrical lines be sure the system is without
pressure and electricity.
ATTENTION!
Operating the machine without paying attention to the safety rules may lead to very
severe injuries. It is essential for the operator to run the machine carefully to avoid
any risks.
Operating the machine without using the provided safety devices, may lead to
severe injuries. Operate the machine only if all safety are at their places working
correctly.

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450 BA
The machine is equipped with the following
safety symbols. These must be always
cleaned and to be substituted when
detached:
1.5 Safety Symbols
Wear gloves mandatory
Read instruction before start the
machine mandatory
Cutting blade
Wear protection glasses mandatory
Entrapment injury
Rotation direction
The saw band may cause injuries during
replacement
The saw blade may cause serious injuries
if obstructed during the cutting
The clamping may cause serious injuries
if obstructed on their way
Blade motor can run in the wrong
direction cause not connected correctly
MEANINGSYMBOL DANGER

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450 BA
2.1 Main characteristics
2. Machine Description
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23 24 17207 15 16
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450 BA
1. 2 Axes numerical control with USB keyfor
updates, easy and fast storage for up to
100 cutting programs with visualization
of all parameters
2. Hydraulic block for a fine regulation of
bow feed and cutting pressure
3. Speed moto-variator, electronic version
Kw 4
4. Graduated plate for miter cutting 0/60°
independent from the plans for pieces
support2
5. Hydraulic devices for vertical clamping
of bars
6. Hardened and carburized jaws for strong
fixture and moving of full bars
7. Safety guards
8. Robust head structure made in one
unique piece of structural steel
9. Wide Plans for piece support for a
comfortable and practical cutting area
10. Roller-unit L=1m for bar support
11. Working light
12. Sensor for monitoring blade rotation
13. Flushing hose
14. Blade tensioning by springs
15. Adjustable Blade-guides with carbide
plates
16. Large basement for easy cleaning
17. Complete coolant equipment inside of
50 Lt. tank with electro-pump 0,12Kw
18. Bimetal blade M42 mm 3660x34x1,1
19. Frame Cylinder
20. Vice Cylinder
21. Movable carriage vice
22. Vertical roller for bars adjusting
23. Electrical cabinet
24. Hydraulic cabinet
• Piece lenght automatically controlled by
a magnetic rule
• Sensor for monitoring blade rotation
in case of blade breakage or sliding on
pulleys
• Frame case protected by a micro-switch
to stop the blade when opened
• Frame height controlled by a
potenziomenter
• Hydraulic stroke of the carriage that
allows to carry on solid material up to
330mm round and 450x240mm plate
• Cardboard box + pallet, service
wrenches, instruction manual and spare
parts list included

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450 BA
CARIF 450 BA
Weight
Dimensions
Sawband
Dimensions
Cutting speed
Working Height
Electrical data
Blade motor
Coolant pump motor
Operating range:
2.2 Technical data
Ca. 1600 Kg
1870 x 2950 x 1550h mm
3660 x 34 x 1,1 mm
15÷100 m/min
830 mm
4 Kw
0,1 Kw
320
250
150
450x240
270x240
170x125
33090°
280+45°
170+60°

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450 BA
The machine must be transported
horizontally.
In case you have to store the machine, take
the following cares:
• Place the machine in a close environment;
• Avoid humid places;
• The storing temperature must not fall
under 5° C (41° F);
• To avoid that the machine might become
rusty, apply the special prevention liquid
where it’s needed.
Usually, the machine is delivered bolted
on a pallet and covered with a cardboard
packing. On this cardboard you can find
machine model references, weight and
manufacturer’s references.
To transport the packed machine you need
a common fork lift.
Before moving the machine from the pallet
to the installation point you need to:
• verify the weight of the machine;
• verify the overall dimensions;
• verify the lifting points.
Aboutliftingofthemachine,inthebasement
there are 4 holes, aimed for the application
of shackles (not standard equipment), in
order to make the grip safer.
3.1 Storage and transportation
3. Installation
While laying and maintenance operating, you need to plan the safest
transport of all the parts of the machine. You need to use suitable equipment,
maneuvered by a skilled sta, in order to avoid to damage the sawing
machine and to cause accidents to the sta.
Use shackles only for the purpose they have been made for.

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450 BA
Fix it on the loading side of the machine by the four screws. Connect the two hydraulic
tubes and fix the cylinder shaft to the driving carriage.
Fix it to the loading side of the machine by the two screws.
Fix it to the standard roller unit (already fixed to the machine). Some roller units may also
be used separately from the machine.
3.3 How to set up the carriage cylinder
3.4 How to set up the standard roller unit for bar support l = 1 m and
how to set up the optional roller unit for bar support
The hexagonal nuts “1” and “2” are pre-adjusted in order to obtain the right
cutting length. Do not unclamp them.
• Please be sure that power supply tension
is conformed to the characteristics of
the machine.
• Environment Temperature between
-10°C (-50°F) and + 50°C (122°F).
• Humidity not more than 90%.
• Ensure to have a working space sucient
to allow the entire safety of the machine.
• Keep the back of the machine at least
800mm (2.6 ft) from the wall.
• Place the machine on a leveled and
straight floor.
• Leveled the machine and eventually
make the foundation in the 4 points of
the basement, as picture below.
3.2 Installation Plan

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450 BA
3.5 Electrical connection
The Electrical connection must be carried out only by qualified personnel
or Electricians.
• Be sure that the coolant tank (part.125) is placed correctly inside the basement.
• Introduce the coolant liquid (water and oil 10%) directly from the back of the machine.
• Capacity 50 Lt (13 Gal).
3.6 Coolant filling
Check if main voltage corresponds to the main voltage on the name plate.
Check rotating direction (arrow on blade motor or frame). If rotation is the wrong
direction, change connection of a phase.
We suggest to use a good quality not toxic cooling liquid, 10% diluted. The
cooling liquid is not supplied with the machine.

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450 BA
3.7 Expulsion of air from the carriage cylinder
Switch ON the machine
On display you can see:
On display you can see: Press:
Press:
CARRIAGE CALIBRATION
Proceed?
<START>Yes <STOP>No
MODE SELECTION
1. Semiautomatic
2. Automatic
3. Machine Parameters
EMERGENCY
CONTROL ENCODER
Press any key
Press a key to ignore message and proceed with carriage operation.
To come back to MODE SELECTION press
By the keys (CARRIAGE BACK) and (CARRIAGE AHEAD) make
the carriage run completely back and completely ahead.
Maybe that the machine stops when meeting air bubbles and you can see the following
message on display:

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450 BA
4.1 Keyboard description
4. Operation
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1. Stop
2. Start
3. Piece Counter +
4. Piece Counter -
5. Blade Speed +
6. Blade Speed -
7. Carriage Forward
8. Carriage Back
9. Open / Close Saw Vice
10. Open / Close Carriage Vice
11. Bow Motion
12. Set of Bar
13. Enter
14. Menu
15. Delete
16. Escape
17. Blade On/O
18. Arrow Keys
19. Cooling System On/O
20. Flanging On/O
21. 0/9 Keys
22.Comma
23.Pause
24.USB port

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450 BA
•Withkeys and  open machine vices and forwarding-carriage vices,
then press
•Position the cutting bar on the machine, without overstep the blade.
•Manualy, by the handwheels, lock machine vices and forwarding-carriage vices against the
cutting bar, then open half-turn the handwheels.
•Adjusttherequiredframeliftingpessingthekey     and contemporaneously
moving the “BOW FEED” lever of the hydraulic control so that between the bar and
the blade there are 3 mm approx.
•Adjusttherequiredcuttingspeed(seeplateonthemachine)bythekeys
and
•Selectbythekey  refrigerationonAUTO(ledwillash).
•Manually to position the bar at required cutting length.
•Press
4.2 Semiautomatic mode
Switch ON the main switch
View on display:
View on display: Press:
Press:
CARRIAGE CALIBRATION
Proceed?
<START>Yes <STOP>No
MODE SELECTION
1. Semiautomatic
2. Automatic
3. Machine parameters

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450 BA
Insert the value and than
confirm ENTER:
(esempio)
Piece Length: 100
4.3 Automatic mode
Switch ON the main switch
View on display:
View on display:
View on display:
View on display:
View on display:
Press:
Press:
Press:
Press:
and
than
CARRIAGE CALIBRATION
Proceed?
<START>Yes <STOP>No
EDIT PROGRAM
Program n. 001
<ENTER>Confirm
PROGRAM N. 001/1
Piece Length: 100
Pieces: 0010 Bars n.: 01
<ENTER>Confirm
MODE SELECTION
1. Semiautomatic
2. Automatic
3. Machine parameters
1. Progr. In Execut.
2. Edit Program
3. Load Program
4. Cancel Program
Pieces: 10
Bars n.: 1

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450 BA
Press
Adjust the “BOW FEED” lever of the hydraulic control in position between “A” and “D” and
the “CUTTING PRESSURE” regulator in position between “1” and “4”, then:
•for NORMAL CUTTING CYCLE (with material on the machine) press
•for MACHINE TEST (without bar on the machine) press
Answer to the following questions:
100
70
5
PROGRAM N. 001
Any other cut on the same
bar?
<START>Yes <STOP>No
PROGRAM N. 001
Insert diameter:
100
<ENTER>Confirm
PROGRAM N. 001
Blade speed m/min:
70
<ENTER>Confirm
PROGRAM N. 001
Flanging mm:
5.0
<ENTER>Confirm
PROGRAM N. 001
Selezione Materiale
1•Round2•Rect.
3•Manualheightreg.
1. Progr. In Execut.
2. Edit Program
3. Load Program
4. Cancel Program
1. Progr. 001 <START>
2. L: 100.0 DIA: 100
3. Pcs:0000/0010 B:01
4. Blade sp.: 70 X: 0.0
LOAD PROGRAM
Program n. 001
<ENTER>Confirm
In this second case, on
display will appear the
following message:
Press and than
EMERGENCY!
Ended Material
<START>Continue Prg
<7>Program Test
to stop cycle.

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450 BA
In AUTOMATIC mode press to access the PROGRAMS LIST.
On the display use buttons and to scroll and select the memorized
program by moving the arrow to the desired program:
In the AUTOMATIC work screen, the number after the piece length indicates the number of
sub-programs in queue:
Press to load the program which is ready for execution.
Press to enter EDIT PROGRAM.
Press o to return to AUTOMATIC MODE.
Press to return to MODE SELECTION.
Press to return to AUTOMATICO MODE.
4.3.1 Programs list
4.3.2 Sub-programs
01 - L = 100.0 1000
L = 200.0 600
RET= 100 m/min = 60
05 - L= 1250.0 50
Progr. n.001 <START>
L: 100.0/01 RET:100
Pcs:0000/0010 B:01
Blade spees: 15 x 0.0

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450 BA
the led is flashing when you restore cycle.
After finishing material, when loading new
bar flanging will be performed.
If in memorized program, flanging is 0,
when you press the led starts to
flash and, while starting the cycle, the CNC
card will perform a flanging cut without
moving the bar.
CYCLE PAUSE is useful when you need to stop momentarily the automatic cycle.
Pressing when cycle is active, the following screen is showed:
The led on button, shows if flanging
is active or not.
When the led is flashing, flanging is
operating, when it is switched o, flanging
is ignored.
If you load a program having a flanging
dierent from 0, the led start to flash,
showing to the operator that, when starting
the cycle, the flanging cut will be performed.
In case of emergency or after a pause of
cycle, flanging will not be performed though
4.4 Cycle pause
4.5 Flanging
CYCLE PAUSE
Piece: 00
<ENTER>Confirm
CYCLE PAUSE
<START>Resume
<STOP>Exit
Insert the number of cuts to perform, before the cycle is pausing
To exit from this screen without programming any pause, press
After performed the programmed pieces, the cycle is pausing:
To resume cycle, press . To go back to the working screen, press

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450 BA
The “Alarm Threshold” shows the maximum stress allowed to the blade. If it’s overcome,
an alarm message is showed: “BLADE STRESS”. To restore allowed values, reduce feed by
“BOW FEED” lever and “CUTTING PRESSURE” regulator.
The “Actual Value” shows the blade stress just in time.
To go out of the screen press
4.6 Set of bars
4.7 Blade stress
Pressing you can modify the number of bars loaded on the sawing machine,
before pressing to start the AUTOMATIC cycle. So, the piece counter will
counting the number of bars to cut simultaneously:
During the cut, you can check the blade stress.
Press . The following screen is appearing:
BARS GROUP
N.Bars: 00
<ENTER>Confirm
BLADE STRESS
Alarm thresh: 4.8A
Actual valur: 2.0A
<ESC>Exit
Insert the new number of bar and press
To go out of the screen without changing the programmed number of bars press