Cosen C2 User manual

COSEN SAWS
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C2
NCFullyAutomatic
HorizontalBandsaw
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InstructionManual
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ThePinnacleofCuttingPerformance
CosenMechatronicsCo.,Ltd.

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NOTE:
Read this instruction manual carefully to familiarize yourself with the installation,
operation and maintenance of your COSEN bandsaw machine.
Operate the machine following the procedures described in the manual to prevent
personal injuries or machine damage.
Keep this manual handy and refer to it whenever you are uncertain of how to
perform any of the procedures.
For technical support or parts purchase, please contact your nearest COSEN
representative or our service center:
For Europe:
email: [email protected]
phone: [phone]
fax: [phone]
web: www.cosensaws.eu
For Taiwan and other countries:
email: [email protected]
phone: [phone]
fax: [phone]
web: www.cosen.com.tw
For US, Mexico, and Canada:
email: [email protected].
phone: [phone]
toll free: +1-877-SAWING1
fax: [phone]
web: www.cosensaws.com
For China:
email: [e-mail]
phone: [phone]
web: www.cosensaws.cn
Instruction Manual: C2
NC Fully Automatic Horizontal Bandsaw
Ver.8 2017/7/24
©2013 by COSEN MECHATRONICS CO., LTD.
No part of this publication may be photocopied or otherwise reproduced without the prior written
permission of COSEN.
Printed in Taiwan
FROM THE MANUFACTURER
Thank you for your purchase of COSEN’s bandsaw machine and your trust in the COSEN
brand.
We are excited to have you as our valued customer and look forward as much as you do to
the accelerated productivity, long-lasting endurance and superb cost-effectiveness this
machine is about to bring to you.
To ensure you are fully utilizing our machine and being advantaged in every possible way,
please do take your time and read through this instruction manual.
Any comment or suggestion in making our service better, please do not hesitate to let us
know. Thank you again!

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Safety rules
Make sure your work area is cleared of uninvited people and obstacles
every time before you start operating the machine.
Never step or stand on the roller table. Your foot may slip or trip on the
rollers and you will fall.
Never wear gloves or loose clothing when operating the machine. It may
lead to serious injury if they are caught in the running machine. Wrap or
cover long hair.

Never touch the running saw blade with gloves or not. It is dangerous if
your hands, clothing or gloves are caught by the running blade.

Make sure any use of fire is prohibited in the shop and install a fire
extinguisher or other fire control device near the machine when cutting
titanium, magnesium, or any other material that produces flammable chips.
Never leave the machine unattended when cutting flammable materials.
Use a water-soluble cutting fluid on this machine. Oil-based cutting fluids
may emit smoke or catch fire, depending on how they are used.

Never cut carbon or any other material that may produce and disperse
explosive dust. It is possible that sparks from motors and other machine
parts will ignite and explode the air-borne dust.

Safety rules

Never adjust the wire brush or remove chips while the saw blade is still
running. It is extremely dangerous if hands or clothing are caught by the
running blade.

Stop the saw blade before you clean the machine. It is dangerous if hands or
clothing are caught by the running blade.

Never start the saw blade unless the workpiece has been clamped firmly. If
the workpiece is not securely clamped, it
will be forced out of the vise
during cutting.
Take preventive measures when cutting thin or short pieces from the work
to keep them from falling. It is dangerous if the cut pieces fall.

Use roller tables at the front and rear sides of the machine when cutting
long work. It is dangerous if the work piece falls off the machine.
Turn off the shop circuit breaker switch before performing maintenance on
the machine. Post a sign indicating the machine is under maintenance.

vi
Table of Contents
Section 1 –Safety Information
1-1
Safety Instructions ………………………………………………………………………………………………………
1-1
Safeguard Devices ……………………………………………………………………………………………………….
1-3
Emergency Stop ………………………………………………………………………………………………………….
1-4
Illustration: Emergency Stop ………………………………………………………………………………………
1-5
Safety Labels ……………………………………………………………………………………………………………….
1-6
Illustration: Safety Labels ………………………………………………………………………………………..…
1-9
Hearing Protection ………………………………………………………………………………………………………
1-10
CE Compliance …………………………………………………………………………………………………………….
1-10
Risk Assessment ………………………………………………………………………………………………………….
1-10
Section 2 –General Information
2-1
Specification ……………………………………..………………………………………………………………………..
2-2
Machine Parts Identification ……………………………………………………………………………………….
2-3
Floor Plan …………………………………………………………………………………………………..……………….
2-4
Section 3 –Moving & Installation
3-1
Location & Environment ………………………………..……………………………………………………………
3-1
Unpacking & Inspecting ……..……………………………………………………………………………………….
3-2
Lifting …………………………………………..………………………………………………………………….………….
3-3
Illustration: Lifting Points ……………………………..……………………………….…………………..
3-5
Removing Shipping Bracket …………………………..……………………………………………….……………
3-6
Cleaning …………………………………………..…………………………………………………………….……………
3-6
Installing …………………………...………………………………………………………………………….…………….
3-6
Supplying Hydraulic Oil …………………………………………………………………….…………….
3-6
Supplying Coolant ………..………………………………………………………………….……………..
3-7
Connecting Electric Power ……………………………………………………………….……………..
3-7
Leveling & Anchoring …………………………………………………………………….……………….
3-8
Installing Roller Table (Optional) ………………………………………………….………………….
3-9
Installing Fire Control Device……………………………………………………………………………
3-9
Relocating ………………………...…………………………………………………………………….………………….
3-9
Section 4 –Operating Instructions
4-1
Safety Precautions …………………..…………………..……………………………………….…………………….
4-2
Before Operating …………………………..…………………………………………………………………………….
4-3
Control Panel ……..……………………………………..………………………………………….…………………….
4-4
Control Panel ………………….………………………………………………………………………..…….
4-4
Control Buttons ……………………………………………………………………………………….……..
4-5

vii
Table of Contents
Blade Descend Pressure & Speed ………..…………………………………………………….……
4-7
HMI Touch Screen & Functions …………………………………………………………….…………
4-7
HMI Error Codes ………………………..……………………………………………………….………….
4-20
Standard Accessories ………….………………………..……………………………………………….……………
4-21
Optional Accessories …….…….………………………..…………………………………………….………………
4-24
Unrolling & Installing the Blade …………………………………………………………………….…………….
4-26
Adjusting Wire Brush ………..……………………………………………………………………….……………….
4-28
Adjusting Saw Arm……………..……………………………………………………………………….………………
4-28
Adjusting Blade Speed ………..………..…………………………………………………………………………….
4-29
Breaking-In the Blade ………..………..…………………………………………………………………..………….
4-29
Placing Workpiece onto Workbed ………………………..……..………..…………………………………….
4-29
Positioning Workpiece for Cutting ………..………..………………………………….……………………….
4-30
Without Using Automatic First Cut Function………………………………………………….
4-30
Using Automatic First Cut Function…………………………………………………………………
4-31
Adjusting Coolant Flow ………..………..…………………………………………………………………..……….
4-32
Test -Running the Machine ....………..……………………………………………..…………………………….
4-33
Cutting Operation ………..………..……………………………………………..…………………………………….
4-34
Using Top Clamp for Bundle Cutting…………………………………………………………………………….
4-35
Terminating a Cutting Operation ………..………..…………………………………….……………………….
4-36
Section 5 –Electrical System
5-1
Electrical Circuit Diagrams ……….…………………..……………………………………………………………..
5-1
Section 6 –Hydraulic System
6-1
Hydraulic Diagrams ……….…………………..………………………………………………………………………..
6-1
Section 7 –Bandsaw Cutting: A Practical Guide
7-1
Introduction ……………………….…….…………………..…………………………………………………………….
7-2
Saw Blade Selection ………………….…………………..……………………………………………………………
7-2
VISE LOADING …………….…………………..………………………………………….………………………………
7-3
BladeBreak -In …………………………………………………………………………………….……………………..
7-4
Section 8 –Maintenance & Service
8-1
Introduction ……………………….…….…………………..…………………………………………………………….
8-1
Basic Maintenance ………………….…………………..…………………………………………….……………….
8-1
Maintenance Schedule …………….…………………..…………………………………………………………….
8-1
Before Beginning a Day’s Work ……………………………………………………………………….
8-2
After Ending a Day’s Work …………………………………………………….………………………..
8-2
Every Month ………………………………………………………………………….……………………….
8-2

viii
Table of Contents
Every Three Months ………………..…………………………………………….……………………….
8-2
Every Six Months ……………….………………………………………………….……………………….
8-3
Storage Conditions …………………………....………..……………………………………………………………..
8-3
Terminating the Use of Machine ……..…………..……………………………………………………………..
8-3
Oil Recommendation for Maintenance ……………………………………………………………………….
8-4
Section 9 –Troubleshooting
9-1
Introduction ……………………….…….…………………..…………………………………………………………….
9-1
Precautions ………………….…………………..…………………………………………………………………….....
9-2
General Troubles & Solutions ………………………..…………………………………………………………….
9-2
Minor Troubles & Solutions ………………………..………………………………………………..…………….
9-3
Motor Troubles & Solutions ………………………..…………………………………………………..………….
9-3
Blade Troubles & Solutions ………………………..………………………………………………………………..
9-4
Sawing Problems & Solutions ………………………..……………………………………………………………
9-5
Re-Adjusting the Roller Table ………………………..…………………………………………………………….
9-12
Section 10 –Parts
10-1
Spare Parts Recommendations …………………..……………………………………………………………….
10-1
Part List …………………..………………………………………………………………………………………………….
10-2
Section 11 –Warranty
11-1
Warranty …………………..………………………………………………………………………………………………..
11-1

1‐1
Section1
SAFETY
INFORMATION

SAFETYINSTRUCTIONS
SAFEGUARDDEVICES
EMERGENCYSTOP
SAFETYLABELS
HEARINGPROTECTION
CECOMPLIANCE
RISKASSESSMENT
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Safetyisacombinationofawell‐designedmachine,operator’sknowledgeaboutthemachineand
alertnessatalltimes.COSEN’sbandmachinehasincorporatedmanysafetymeasuresduringthe
designprocessandusedprotectivedevicestopreventpersonalinjuriesandpotentialrisks.Warning
labelsalsoserveasaremindertotheoperator.

Throughoutthismanual,youwillalsoseevarioussafety‐relatedsymbolsindicatingimportant
informationthatyoushouldtakenoteofpriortouseofthemachineorpartofitsfunctions.These
importantsafetyinstructionsdonotcoverallpossiblesituationsthatmightoccur.Itisyour
responsibilitytotakecautionandfollowproceduresstatedinthismanualwheninstalling,
maintainingandoperatingyourmachine.Cosenwillnotbeliablefordamagesresultingfrom
improperuse.


SAFETYINSTRUCTIONS
Whattheiconsandsignsinthisusermanualmean:

ThisiconmarksDANGER;hazardsorunsafepracticesthatmayresultinsevere
personalinjuryordeath.

ThisiconmarksWARNING;hazardsorunsafepracticesthatmayresultin
personalinjuryordamagetothemachine.

ThisiconmarksCAUTION;informationthatshouldbereadbeforeusetoprevent
damagetothemachine.
Supplementaryinformationtotheproceduresdescribedinthismanual.
Callyourlocalagentorourservicecenterforhelp.

1‐2


Thismanualhasimportantsafety
information.Readthroughitcarefully
beforeoperatingthismachinetoprevent
personalinjuryormachinedamage.Learn
theoperation,limitationandthespecific
potentialhazardspeculiartothisband
saw.

Donotoperatethismachineunlessitis
completelyassembled.

Makesurethepowerswitchisoffbefore
plugginginpowercord.

Disconnectthepowercordbeforemaking
adjustment,maintenanceorblade
changes.

Keepallguardsandshieldsinplacebefore
installingorstartingupthemachine.

Wearproperapparelduringoperation
andwhenservicingthemachine.
Keepunauthorizedpersonnelaway.

Donotreachoverorstandonanypartof
themachine.

Neverholdthematerialbyhandfor
cutting.Alwaysusetheviseandmake
surethematerialisclampedsecurely
beforecutting.

Itisdangeroustooperatethemachine
whenthefloorisslippery.Keepthefloor
cleananddry.Checkforice,moisture,or
greasebeforeentering.

Donotusethemachinetocutexplosive
materialorhighpressurevesselsasitwill
generategreatamountofheatduringthe
sawingprocessandmayignitean
explosion.

Keeptheworkenvironmentsafe.Donot
usebandsawinadamporwetlocation.

Neveroperatewhileundertheinfluence
ofdrugs,alcoholormedication.

Allusersmustreaditbeforeperformingany
activityonthemachine,suchasreplacing
thesawbandordoingregularmaintenance.
Somepersonalprotectiveequipmentis
requiredforthesafeuseofthemachine,e.g.
protectiongoggles.
Keepbladeprotectioncoverandwheel
coversinplaceandinworkingorder.
Userecommendedaccessories.Improper
accessoriesmaybehazardous.
Keepyourworkareawellilluminatedat
minimum500lumen.
Keepyourworkareaclean.Clutteredand
slipperyfloorsinviteaccidents.
Removeadjustingkeys,wrenchesorany
loosepartsoritemsfromthemachine
beforeturningonpower.
Checkfordamagedparts.Beforecontinuing
usingthemachine,thedamagedpartshould
becheckedandreplaced.
Movingpartsshouldbekeptinproper
alignmentandconnectionwiththemachine.
Checkforbreakage,mountingandanyother
conditionsthatmayaffectitsoperation.Any
damagedpartorguardshouldbeproperly
repairedorreplaced.
Whenaworkpieceistoolongorheavy,
makesureitissupportedwitharollertable
(recommended).
Alwaysremembertoswitchoffthemachine
whentheworkiscompleted.
Useasharpsawbladeandkeepthemachine
initsbestandsafestperformanceby
followingaperiodicalmaintenanceschedule.
Donotforcethebandsawbeyondits
intendeduse.Itissafertooperatewiththe
cuttingrateforwhichitwasdesigned.


1‐3
SAFEGUARDDEVICES
Thesafeguarddevicesincorporatedinthismachineincludethefollowingtwomainparts:
1. Protectioncovers&guards
2. Safety‐relatedswitches

ProtectionCovers&Guards
1. Idlewheelhousingcover
2. Drivewheelhousingcover
3. Gearreducercover
4. Wirebrushbeltcover
5. Bladeguardcover(left&right)
6. Chipconveyorcover(CEmodelonly)

Theprotectiondevicesshouldalwaysbemountedonthemachinewheneverthemachineisrunning.
Donotremoveanyofthesesafeguarddevicesunderanycircumstancesexceptwhenservicingthe
machine.Evenskilledservicetechniciansshouldstilltakecautionswhenperformingrepairsorservice
onthemachinewithanyoftheseprotectorsremoved.Itistheresponsibilityoftheusertomakesureall
theseelementsarenotlostanddamaged.
Takenoteofthefollowingmainmovingpartsonthemachinepriortoandduringmachineoperation:
Sawbowassembly
Driveandidlewheels
Bladeguidearm
Sawbladeguiderollers
Quickapproachdevice
Wirebrush
Chipconveyor(optional)
Workpiececlampingvises
Shuttlevisesandworkbedrollers
Topclamps(optional)
Gearreducer


1‐4
SafetyRelatedSwitches
Toprotecttheoperator,thefollowingsafetyrelatedswitchesonthemachineareactuatedwhenthe
machineisinoperation.

WheelmotiondetectorThisisaproximitysensorusedtodetectthemotion
ofthedrivewheel.Oncethesawbladeisbrokenor
assoonasitstartsslipping,thesensorwilldetect
andstopthedrivewheelandthemachine.
PowerswitchLocatedonthecoverofelectricalcabinet,thepower
switchcontrolsthemainpowerofthemachine.
EmergencystopbuttonLocatedonthecontrolpanel,thebuttonwhen
pressedwillstopthemachinecompletely.
ViseclampswitchThisswitchassuresfirmclampingoftheworkpiece.If
theworkpieceisnotclampedproperly,thesaw
bladeisnotallowedtorun.
Wheelcoverinterlockswitches
(CEmodelonly)
Locatedonthetwowheelhousings,theseswitches
areusedtoassurethatthemachinewillstop
wheneverthewheelcoversareopen.Thisdeviceis
toprotectusersfrombeingcutbytherunningsaw
blades.

Amongallthesesafetyswitches,someofthemareusedtoprotecttheusersandsomeofthemare
usedtopreventdamagetosawblades,theworkpieceandthemachineitself,etc.Wehavetaken
everyprecautiontopreventinjuryordamageandtoprovidesafeandeconomicaloperationofthe
machine.


EMERGENCYSTOP
Designedtobeeasilyaccessible,theemergencystopbuttonislocatedontheleftbottomcorneron
thecontrolpanelandismadeinredcolorandrubbermaterial.ForCEmodels,supplementary
emergencystopbuttonmaybeavailableatotherarea(s)ofthemachinedependingonmachinetype.
PleaserefertoIllustration:EmergencyStop.
Whenyoupressthebutton,themachinewillimmediatelycometoafullstoptoavoidinjuryor
damagewhenanaccidentoccurs.Thebuttonwillbelockedwhenyoupressit.Tounlockit,pullit
upward.
Youshouldpressitimmediatelywithoutanyhesitationwhenobserving:
Anemergencysituationthatwouldcauseanyinjuryordamage
Anabnormalsituationorproblemsuchasfire,smoke,abnormalnoiseandetc.



1‐5
Illustration:EmergencyStop






EmergencyStop

1‐6
SAFETYLABELS
Safety‐relatedlabelsmountedonthemachinearecategorizedintothefollowingfourcategories.
Pleasereadthroughandunderstandthembeforeoperatingthemachine.RefertoIllustration:Safety
Labels.

DANGERLabels
AredandwhiteDANGERlabelsmarksshazardsorunsafepracticesthatwillresultinseverepersonal
injuryordeath.
LabelMeaningLabelMeaning

HazardousVoltage

TURNPOWEROFFbefore
servicing.Failureto
followingthewarningcan
resultinsevereinjury.

DANGER:RunningBlade
Bladerunsthroughthisarea.Keep
yourhandsawayfromarunning
bladetoavoidsevereinjury.The
arrowindicatesdirectionofthe
blade.


WARNINGLabels
AnorangeandblackWARNINGlabelmarkshazardsorunsafepracticesthatcanresultinsevere
personalinjuryordamagetothemachine.
LabelMeaningLabelMeaning

CuttingHazard

KEEPCOVERCLOSEDwhile
thebladeisrunning.Turn
poweroffbeforeopening
cover.Failuretofollowthe
warningcanresultinsevere
injury.
CuttingHazard

KEEPHANDOFFwhilethebladeis
running.Turnpoweroffbefore
openingcover.Failuretofollowthe
warningcanresultinsevereinjury.


Pleaseaddantifreeze
coolantwhentheambient
temperatureisbelow0˚C
(32˚F).

LooseHandHazard

KEEPHANDOFF.Donottouchchip
conveyor.Failuretofollowthe
warningcanresultinsevereinjury.

ImpactHazard

WEARSAFETSHOES.Donot
approachdroppingarea
duringoperation.



1‐7
CAUTIONLabels
YellowandblackCAUTIONlabelsmarkhazardsorunsafepracticesthatcanresultin
considerablepersonalinjury.
LabelMeaning

Keephandsoutofthemachinewhilethebladeisrunning.

Powertomachinemustbeturnedoffwhenchangingbladesor
adjustingwirebrush.


NOTICELabels
BlueandwhiteNOTICElabelsmeanunsafepracticesthatcouldresultindamagetoproductsor
property.
LabelMeaning

Replacethehydraulicoileverysixmonthsorevery1,200hours
ofoperation.

Oilspecification:ShellTELLUS27orMobilDTEOILLIGHT/
HYDRAULIC28

Toextendbladelife,alwaysadjustthelocationofwirebrushso
thatitisproperlytouchingtheblade.Alsoreplaceawornwire
brushwithanewone.



1‐8
SAFETYINSTRUCTIONLabels
GreenandwhiteSAFETYINSTRUCTIONSareimportantremindersthatshouldbereadbefore
operatingthemachine.
LabelMeaning
1. Readandunderstandtheinstructionmanualandwarning
signsbeforeoperatingmachine.Failuretofollowthese
instructionsandwarningscanresultinseriousinjuryor
death.
2. Donotweargloves,neckties,jewelryorlooseclothing
whileoperatingthemachine.
3. Alwaysweareyeprotectiongoggles.
4. Checkbladetensionandadjustbladeguidebeforestarting
tocut.
5. Alwaysclampstockfirmlyinplacebeforecutting.
6. Donotremovejammedorcut‐offpiecesuntilbladehas
stopped.
7. Keepfingersoutofpathofblade.
8. Bladeguardsshouldbeinplaceandusedatalltimes.
9. Disconnectmachinefrompowersourcebeforemarking
repairsoradjustments.
10. Donotoperatewhileundertheinfluenceofdrugs,alcohol
ormedication.


1‐9
Illustration:SafetyLabels


1‐10
HEARINGPROTECTION
Alwaysuseearprotection!
Whenyourmachineisrunning,noisegeneratedbythemachinemaycomefromthefollowing:
Sawbladeduringcuttingormaterialfeedmechanism
Wirebrushunit
Chipconveyorunit
Speedreducer
Hydraulicmotor/pump
Belttransmissionsvariablespeedmotors
Blademotor
Coolantpump
Drivewheel
Partsnotassembledtightlycausingmechanicalvibration

Ourproductspassnoisetestinglessthan78dBA.Noiselevelvaryaccordingtoworkingconditions
andwerecommendearplugsorotherhearingprotectionatalltime.Ifyourmachineproducesan
undesirablenoisewhileitisrunning,youshould:
1. Makesureallmaintenancetaskshavebeenperformedfollowingtheprescribedmaintenance
schedule(RefertoSection8).
2. Ifmaintenancedoesnotseemtosolvetheproblem,followthetroubleshootingprocedures
underSection9.


CECOMPLIANCE
Cosen’sCEmodelisdesignedtosatisfyregulationsoftheCouncilDirectiveontheapproximationof
thelawsoftheMemberStatesrelatingtomachinery(2006/42/EC)‐AnnexIEssentialhealthand
safetyrequirementsrelatingtothedesignandconstructionofmachinery.


RISKASSESSMENT
Riskassessmentgenerallytakesaccountofintendeduseandforeseeablemisuse,includingprocess
controlandmaintenancerequirements.Wemadeeveryefforttoavoidanypersonalinjuryor
equipmentdamageduringthemachinedesignstage.However,theoperator(orotherpeople)still
needstotakeprecautionswhenhandlinganypartofthemachinethatisunfamiliarandanywhereon
themachinethathaspotentialhazards(e.g.theelectricalcontrolbox).


