RIEXINGER BSM 631 User manual

Translation of the original operating manual
Operating manual
Band-saw machine for plastic pipes
Type BSM 631 / BSM 800 / BSM 1000

Status April 2016
© Eugen Riexinger GmbH & Co. KG

1
Table of contents
1. Important basic information 5
1.1 Operator evaluation 5
1.2 Legal notice 5
1.3 Safety symbols 5
1.4 Used notation styles 6
1.5 Used abbreviations 6
1.6 Location of objects in the room 7
1.7 Labelling on the machine 8
2. Basic safety instructions 9
2.1 Behaviour in case of emergency 9
2.2 Follow the operating manual 9
2.3 Usage according to regulations 9
2.4 Improper usage 10
2.5 Personnel requirements 10
2.6 Informal safety measures 12
2.7 Properly functioning of protective devices 12
2.8 Organizational measures 12
2.9 Other hazards 12
2.9.1 Fire hazard 13
2.9.2 Electrical hazards 13
2.9.3 Laser radiation (optional) 13
2.9.4 Mechanical hazards 14
2.9.5 Heat hazards 14
2.9.6 Environmental hazards 14
3. Technical data 15
3.1 General information 15
3.2 Delivery contents 16
3.3 Dimensions and weight 16
3.4 Equipment 16
3.5 Workpieces 17
3.6 Electrical connection 17
3.7 Pneumatic connection (optional) 18
3.8 Suction of saw shavings 18
3.9 Emissions 18
4. Setup and function 21
BSM 631 / BSM 800 / BSM 1000

2
4.1 Overview 21
4.2 Functionality 22
4.3 Safety concept 22
4.3.1 Emergency-off circuit 22
4.3.2 Safety button 23
4.3.3 Further safety equipment 23
5. Delivery, in-company transport and storage 25
5.1 Delivery 25
5.2 Environmental conditions for storage and transport 25
5.3 In-company transport 25
6. Setup and activation 27
6.1 Setup location 27
6.1.1 Floor conditions 27
6.1.2 Lighting 27
6.2 Environmental operating conditions 27
6.3 Setup plan 28
6.4 Setting up the machine 29
6.5 Connect to electrical power supply 30
6.6 Establish pneumatic connection (optional) 30
6.7 Connect to suctioning (optional) 31
6.8 Initial operation 31
7. Operation 33
7.1 Before start-up 33
7.2 Protective equipment 33
7.3 Turning the BSM 631 / BSM 800 / BSM 1000 on and off 33
7.4 Control panel 34
7.5 Foot pedal (optional) 35
7.6 Setting the saw feed rate 35
7.7 Setting the sawing angle 37
7.8 Loading the machine 38
7.9 Space between saw-band guide and workpiece 42
7.10 Sawing 43
8. Finding and repairing malfunctions 45
8.1 Reparing mechanical malfunctions 45
8.2 Repair electrical malfunctions 46
8.3 Check saw-band motor 47
8.4 Setting lower limit switch 48
BSM 631 / BSM 800 / BSM 1000

3
8.5 Set optical cut indicator (optional) 49
8.6 Guarantee 50
8.7 Error report 51
9. Maintenance 53
9.1 Cleaning the machine 54
9.2 Tensioning the saw band 55
9.3 Removing the saw band 58
9.4 Inserting the saw band 60
9.5 Greasing 62
9.6 Check safety equipment 64
9.7 BSM 631 / BSM 800 / BSM 1000 maintenance 66
10. Dismantling and disposal 69
10.1 Deactivation 69
10.2 Final shutdown 69
10.3 Disposal 69
11. Annex 71
11.1 Contact form 71
11.2 EC Conformity Declaration 73
11.3 Dimenson sheets 75
11.3.1 Dimension sheet BSM 631 75
11.3.2 Dimension sheet BSM 800 77
11.3.3 Dimension sheet BSM 1000 79
11.4 Circuit diagram 81
11.5 Pneumatic diagram (optional) 82
12. Other informations 83
BSM 631 / BSM 800 / BSM 1000

4
BSM 631 / BSM 800 / BSM 1000

1. Important basic information 5
1. Important basic information
1.1 Operator evaluation
Dear operator,
Our operating instructions are updated on a regular basis. Your suggestions for improvement
help us create an increasingly user-friendly operating manual. Please use the contact form for
your suggestions (see Chap. 11 on p. 71).
1.2 Legal notice
Without explicit, written authorisation of the company Eugen Riexinger GmbH & Co. KG the
operating manual may not be electronically or mechanically copied, distributed, changed, for-
warded, translated into another language nor used in any other way.
The company Eugen Riexinger GmbH & Co. KG is not liable for damages resulting from non-
or partial compliance with the operating manual.
1.3 Safety symbols
This operating manual uses the following designations and symbols for hazards:
Danger!
This symbol refers to an immediate danger to the life and health of a person.
Disregarding such notices results in severe harm to a person and may even cause
fatal injuries.
Warning!
This symbol refers to a potentially immediate danger to the life and health of a
person.
Disregarding such notices may result in severe harm to a person and may even
cause fatal injuries.
Caution!
This symbol refers to a potentially harmful situation.
Disregarding such notices may result in minor harm to a person or material dam-
age.
BSM 631 / BSM 800 / BSM 1000

61. Important basic information
Attention!
This symbol gives important information for properly handling the machine.
Disregarding such notices may result in malfunctions or material damage of the
machine or cause damage to the environment.
Information
This symbol provides instructions and particularly useful information. Such infor-
mation helps you use all functions of your machine optimally.
1.4 Used notation styles
This operating manual uses the following notation styles:
lWords or sentences with emphasised meaning are written in italics.
lControl elements on the control panel are written in blue font.
lThe instructions, which the operator follows to perform specific functions, always begin
with a number or a letter. Activities or notifications, which the machine uses as a response
to executed instructions, are marked with a preceding full stop, e.g.:
1. Instruction
a. Instruction
lResponse or notification from machine
1.5 Used abbreviations
IndSafReg Industry Safety Regulations (German implementation of Guideline 2009/104/EG)
DGUV
Roule 3
German Social Accident Insurance (electrical facilities and manufacturing equip-
ment) of the Professional Association for Health and Social Welfare
BSM Band saw machine
GFP Glass fibre-reinforced plastic
PE Polyethylene (thermo-plastic synthetics)
PP Polypropylene (partial crystalline thermo-plastic synthetics)
PVDF Polyvinylidene fluoride (opaque, partial crystalline thermo-plastic fluorine syn-
thetics)
APR Accident Prevention Regulations
BSM 631 / BSM 800 / BSM 1000

1. Important basic information 7
1.6 Location of objects in the room
The spatial information about locations of objects in the room in relation to the BSM 631 / BSM
800 / BSM 1000 always refer to the image below.
BSM 631 / BSM 800 / BSM 1000

81. Important basic information
1.7 Labelling on the machine
Symbol Attachment location Meaning
Saw bow (near the saw
band)
Warning of severance- and cut injury
caused by saw band
Saw bow (near the opti-
cal cut indicator,
optional)
Warning of laser beams
Switchboard cabinet
Control panel
Electrical components
Warning of dangerous electrical voltage
when opening the door of the switchboard
cabinet or the control panel casing or touch-
ing electrical components
Pneumatic pipe tension
(optional)
Warning of crushing between the fixed and
moving machine parts
TYPE LABEL Switchboard cabinet Type label and CE marking of the BSM
631 / BSM 800 / BSM 1000
BSM 631 / BSM 800 / BSM 1000

2. Basic safety instructions 9
2. Basic safety instructions
This chapter contains basic safety instructions for operating the BSM 631 / BSM 800 / BSM
1000 safely.
2.1 Behaviour in case of emergency
Warning!
Running saw band may injure the operator!
The saw band has a delayed stop-time of 4 seconds.
After pressing the emergency-off button or deactivating the main switch, wait
until the saw band has come to a complete stop before entering the saw-band
area.
How to shutdown the machine in an emergency:
1) Press the emergency-off button on the machine's control panel (see Chap. 7.4 on p. 34).
2) Turn the machine off with the main switch at the switchboard cabinet (see Chap. 7.3 on p.
33).
3) Call for an authorised person who can discover the reason for the emergency and fix the prob-
lem.
2.2 Follow the operating manual
lCarefully read this operating manual before using the machine for the first time.
lFamiliarize yourself well with all safety instructions contained therein and observe these
at all times when working with the machine.
lAlways keep the operating instructions on hand near the machine.
lIf the machine is transported to a new location, give these instructions to the new oper-
ator.
2.3 Usage according to regulations
The BSM 631 / BSM 800 / BSM 1000 is exclusively designed for sawing pipes with the prop-
erties and dimensions outlined in this operating manual (see Chap. 3.5 on p. 17). Proper usage
also includes:
lObserving all guidelines from the operating manual and
lAdhering to maintenance intervals
BSM 631 / BSM 800 / BSM 1000

10 2. Basic safety instructions
The BSM 631 / BSM 800 / BSM 1000 is exclusively intended for usage in industry, craft and
trade. It is not intended for private usage.
2.4 Improper usage
The BSM 631 / BSM 800 / BSM 1000 may not be -
loperated by more than one person (exceptions are described in the respective context);
loperated with deactivated safety button when the operator has not implemented the appro-
priate protective measures (e.g. safety fence) to keep the hazard area clear of people dur-
ing operation;
loperated with deactivated safety button without operator supervision (with automatic saw
feed);
loperated when not all protective equipment are available or fully functional:
loperated when malfunction and defects have not been repaired:
lmodified or changed;
loperated in an explosive atmosphere;
loperated in a dusty environment without appropriate ventilation;
lbe operated outdoors but only in inside rooms.
Furthermore, it is also not permissible to -
lmodify the performance or the rotational speed of the motors;
lbypass the safety button, the end switch, the control elements or other control com-
ponents;
lsaw materials that are not intended for the machine BSM 631 / BSM 800 / BSM 1000 as
e.g. wood or metal;
lwork on the machine without the personal protective gear prescribed in this operating
manual.
lwork on the machine with influence of alcohol, drugs and/or medicines.
2.5 Personnel requirements
The BSM 631 / BSM 800 / BSM 1000 may only be operated by trained personnel whom the
operator has authorised.
Personnel who are still learning how to work with the machine or apprentices may only operate
it under the constant supervision of an instructed person.
BSM 631 / BSM 800 / BSM 1000

2. Basic safety instructions 11
Instructed person
A person who is at least 18 years old and has been sufficiently instructed or
supervised by a trained employee and is therefore able to recognize risks and
avoid hazards.
Authorised person
lPerson who has a reliable understanding of safety-related technological
issues due to professional expertise acquired through training, experience
and recent professional activities
lThe authorised person must have knowledge of state-of-the-art technology
for the tasks to be executed and recognise hazards; he must also maintain
this state of expertise.
Warning!
Electrocution hazard!
Only professional electricians may perform work on the machine's electrical
equipment according to the electro-technological regulations.
Thefollowing table shows the personnel that is allowed to work with the machine in a par-
ticular life-phase the qualifications that this person must possess.
Life-phase Instructed person Authorised person
Transport – +
Installation – +
Activation – +
Operation + +
Malfunction search + +
Maintenance + +
Storage – +
Deactivation – +
Dismantling – +
Disposal – +
BSM 631 / BSM 800 / BSM 1000

12 2. Basic safety instructions
2.6 Informal safety measures
lAlways keep the operating instructions on hand near the machine.
lIn addition to this operating manual, adhere to general and local accident prevention- and
environmental protection regulations.
lEnsure that all safety instructions and danger notices attached to the machine (see Chap.
1.7 on p. 8) are legible and replace them if necessary.
2.7 Properly functioning of protective devices
All protective devices must be installed and function properly before starting up the machine
(see Chap. 7.2 on p. 33).
Protective devices may be removed for repair work -
lafter the machine is idle and
land after the machine has been secured against re-activation (e.g. locking the main
switch).
2.8 Organizational measures
The proprietor of the BSM 631 / BSM 800 / BSM 1000 is obligated to provide the required per-
sonal protective equipment. The personal protective equipment includes:
lWork clothing
lSafety glasses
lProtective gloves
lHearing protection
lLifting device for loading and unloading of pipes to be sawed
lClimbing aid for maintenance
Do not wear loose clothing, bracelets, necklaces or other objects that could get caught in the
moving parts of the machine.
Furthermore, the proprietor must ensure the regular examination of all existing safety equipment
(see Chap. 9.6 on p. 64).
2.9 Other hazards
In the following you will find the overridingly valid safety instructions that are relevant for sev-
eral of the BSM 631 / BSM 800 / BSM 1000 life phases. Specific safety instructions are listed
in the relevant sections of this operating manual.
BSM 631 / BSM 800 / BSM 1000

2. Basic safety instructions 13
2.9.1 Fire hazard
Warning!
Fire hazard due to plastic waste
lKeep ignition sources away from the work area.
lDo not smoke in the work area.
lEnsure that no open fire ignites in the work area.
Fire protection
lNever use water to extinguish a fire source; always use sand, carbon dioxide or powder.
lIt is imperative to turn off the machine at the main switch or disconnect the power supply
before extinguishing a fire source.
2.9.2 Electrical hazards
Warning!
Directly or indirectly touching live parts may result in electrocution.
lTurn off the main switch before opening the door of the switchboard cab-
inet.
lPull the power plug or deactivate the power supply before working on elec-
trical components.
lElectrical components are not protected against spray water. The proprietor
must implement appropriate protective measures.
2.9.3 Laser radiation (optional)
Information!
Important informations about the laser!
lThe used laser is a laser class 1 according to DIN EN 60825-1:2008-05.
The accessible laser radiation is harmless.
BSM 631 / BSM 800 / BSM 1000

14 2. Basic safety instructions
2.9.4 Mechanical hazards
Danger!
Running saw band may cause serious severance injury!
Descending saw bow may pinch the operator!
lThe machine may only be operated by one person.
lBefore running the saw band or lowering the saw bow, the operator must
ensure that the area behind the workpiece and the work area are clear.
Danger!
Climbing onto the machine poses a fall- and injury risk due to sharp machine
parts!
It is not permissible to climb onto the machine when performing maintenance- or
any other kind of work. Use suitable climbing aids (e.g. stepladders or multi-pur-
pose ladders, but no leaning ladders).
2.9.5 Heat hazards
Attention!
After sawing the hot saw band may burn the operator!
Wear protective gloves during repair work or allow the saw band to cool down
before touching it.
2.9.6 Environmental hazards
Attention!
Plastic waste and used saw bands contaminate the environment!
Dispose of all shavings, plastic waste and used saw bands according to locally
applicable legal stipulations.
BSM 631 / BSM 800 / BSM 1000

3. Technical data 15
3. Technical data
3.1 General information
Machine construction
lRobust, torsion-resistant machine stand and saw frame made of steel
lSaw-band redirection with ball bearings
lCompensation for warmth-induced expansion of the saw band with band-tensioning
device
Cut quality
lPrecision guides for straight cuts
lAdjustable saw-band guide for straight cuts
lHigh saw-band speed for optimal cut quality
lSeamlessly adjustable feed rate of saw bow for various materials and wall thicknesses
Operation
lTensioning of workpieces with clamping belts
loptional: Pneumatical pipe clamping for fast and secure clamping of workpieces
lV-Support for pipes with small diameters (optional)
lExact adjustment of saw angle possible with angle scale at front
lMitre area of 45 degrees on both sides with swivel-mounted saw bow (optimal for man-
ufacturing curved segments)
lVisual cutting indicator for quick positioning of workpiece (optional)
lAutomatic cutting depth limit
lAutomatic air blow system to clean saw band (optional)
lcontrol panel
BSM 631 / BSM 800 / BSM 1000

16 3. Technical data
3.2 Delivery contents
The delivery contents of the BSM 631 / BSM 800 / BSM 1000consist of:
lBSM 631
l2 Saw bands for polyester pipes
lcontrol paneel
l6 Screw feet
l2 tension belts
l1 Operating Manual
3.3 Dimensions and weight
BSM 631 BSM 800 BSM 1000
Length 2300 mm 2800 mm 3800 mm
Width at straight cut 2800 mm 3250 mm 3700 mm
Width at angle cut 2300 mm 2400 mm 2800 mm
Maximum Height (completely raised saw bow) 2800 mm 3250 mm 3700 mm
Weight ca. 450 kg 650 kg 980 kg
Transport dimensions
BSM 631 BSM 800 BSM 1000
Length 2700 mm 2800 mm 3800 mm
Width 2300 mm 2400 mm 2800 mm
Height 2070 mm 2300 mm 2450 mm
3.4 Equipment
Saw band
BSM 631 BSM 800 BSM 1000
Dimensions in
mm
Art.-No. 300231
6280 x 25 x 0,9
Art.-No. 301288
7340 x 25 x 0,9 mm
Art.-No. 302256
8140 x 25 x 0,9
Tooth pitch(Tz) 4 bzw. 6 ZpZ (depending on wall thickness of workpiece)
BSM 631 / BSM 800 / BSM 1000

3. Technical data 17
Caution!
Saw bands that jump off the spool may injure the operator or cause material
damage.
Use original saw bands from the machine's manufacturer. Saw bands from other
providers may jump off the spool and injure the operator or cause material dam-
age to the machine or workpiece.
3.5 Workpieces
Type of material PE, PP, PVDF plastics (other types of plastics after consultation
with manufacturer)
Profile Pipe with circular cross-section (devations from circular cross-sec-
tion permissible up to ca. 50 mm)
BSM 631 BSM 800 BSM 1000
min. diameter in mm 200 200 315
max. diameter in mm 630 800 1000
min. length The workpiece must be tensioned sure.
Attention!
The BSM 631 / BSM 800 / BSM 1000 may only be used to saw glass fibre-rein-
forced plastics when the GFP-dust is ventilated with a ventilation system.
Dust is released into the air when sawing GFP, and this dust can very quickly
shutdown mechanical components and electrical equipment of the BSM 631 /
BSM 800 / BSM 1000. Therefore, a suitable ventilation system is absolutely nec-
essary when sawing GFP.
3.6 Electrical connection
BSM 631 BSM 800 BSM 1000
Operating voltage 400 V 3~/N/PE
Frequency 50 Hz
Power rating 5 kVA 5kVA 7,1kVA
Connection Type CEE-plug-in, 32 A, 400 V
Phase sequence Field turning clockwise
BSM 631 / BSM 800 / BSM 1000

18 3. Technical data
Saw band operation
BSM 631 BSM 800 BSM 1000
Mechanical output
with overload protection
with electrical brake
2,5 kW 2,5 kW 4,0 kW
Saw bow motor
BSM 631 BSM 800 BSM 1000
Mechanical otuput
with overload protection
Rotational speed control
via frequency inverter
0,37 kW 0,37 kW 0,5 kW
3.7 Pneumatic connection (optional)
Minimum pressure 5 bar
Operating pressure 6 bar
Maximum pressure 8 bar
Connection 1/4" plug fitting
3.8 Suction of saw shavings
Shavings produced during cutting of plastic pipes can be removed by suction. For this machine
must be connected to an suction system.
3.9 Emissions
Dust
Caution!
Sawing plastic materials releases fine dust into the air, which may harm the
operator's health!
lAdhere to the respective legal regulations and determined workplace
threshold values for dust.
lThe proprietor is obligated to install a ventilation system and provide the
operator with a respiratory mask if workplace threshold values are
exceeded.
BSM 631 / BSM 800 / BSM 1000