Temelsan DK 1500 LS User manual

DK 1500 LS
PLC CONTROLLED VERTICAL
BANDSAW MACHINE

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
INDEX
1. ABOUT US ............................................................................................................... 4
2. CONDITIONS OF OPERATION .................................................................................... 5
3. SAFETY STIPULATIONS ............................................................................................ 5
4. SAFETY SIGNS ON THE MACHINE AND THEIR MEANINGS ............................................ 6
5. GENERAL DESCRIPTION OF THE MACHINE ................................................................ 7
5.1. Description of the Machine..................................................................................... 7
5.2. Expansion of the Model Name................................................................................. 7
5.3. List of Machine Models .......................................................................................... 7
5.4. Machine type and Specifications ............................................................................. 8
5.4.1. Machine type: DK-1500-LS.................................................................................. 8
5.4.2. Machine specifications........................................................................................ 8
6. Sample of Machine Name Plate .................................................................................. 9
7. GENERAL PRINCIPLE OF OPERATION ...................................................................... 10
8. PREREQUISITS OF TRANSPORTATION ..................................................................... 11
8.1. Transportation style............................................................................................ 11
8.2. Precautions........................................................................................................ 11
8.3. Conditions for transportation ............................................................................... 11
Congragulations to your new TEMELSAN VERTICAL BANDSAW MACHINE DK 1500 LS…

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
8.4. Storing Conditions .............................................................................................. 11
9. INSTALLATION AND OPERATIONAL INSTRUCTIONS ................................................. 12
9.1. UNLOADING....................................................................................................... 12
9.2. INSTALLATION................................................................................................... 13
9.3. OPERATIONAL INSTRUCTIONS ............................................................................ 15
9.3.1. Operation of the Machine.................................................................................. 15
10. TRAINING .......................................................................................................... 16
11. SPARE PART LIST ............................................................................................... 16
12. SERVICE ............................................................................................................ 16
13. PLANNED MAINTENANCE CHART ........................................................................ 17
13.1. DAILY MAINTENANCE...................................................................................... 17
13.2. WEEKLY MAINTENANCE.................................................................................. 17
13.3. MONTHLY MAINTENANCE ............................................................................... 17
13.4. BI-ANNUAL MAINTENANCE.............................................................................. 17
14. TROUBLESHOOTING ........................................................................................... 17
15. GUARANTEE CERTIFICATE .................................................................................. 22
16. DECLARATION OF CONFORMITY.......................Hata! Yer işareti tanımlanmamış.
CONTROL PANEL......................................................................................................... 24
USER LOGIN AND LOGOUT .......................................................................................... 25
PASSWORD CONFIGURATION...................................................................................... 33
I-O TRACKING PAGES.................................................................................................. 38

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
ALARM & WARNING LIST AND TROUBLESHOOTTING.................................................... 47
FUNCTION OF MANUAL HYDRAULIC VALVE .................................................................. 54
Given Tention to the bandsaw blade : ....................................................................... 54
Loosen Tension on bandsaw blade and change the blade :......................................... 55
BLADE CHANGE INSTRUCTION .................................................................................... 55
APPENDICES ............................................................................................................... 55
Appendix 1 Exploded Views and Technical Representation of Parts or Main Units ................ 56
FREE WHEEL AND SHAFT ......................................................................................... 56
MAIN BLADE MOTOR SHAFT..................................................................................... 57
TENTION WHEEL AND SHAFT................................................................................... 58
RACK (GUIDE POST) ................................................................................................ 59
BLADE GUIDES ........................................................................................................ 60
HYDRAULIC UNIT .................................................................................................... 61
TENSION VALVE ...................................................................................................... 62
BALLSCREW AND SERVO MOTOR.............................................................................. 63
Appendix 2 Electrical Diagrams ...................................................................................... 65

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
1. ABOUT US
Temelsan, by the in-depth experience in the business, utilizing the latest technology sustains the
continuous production of machines.
Temelsan gained a unique status in production of flash butt welding machines beside the
manufacture of bandsaw machines all around the world. There are numerous customers who
are using Temelsan brand flash butt welding machines; not only the bandsaw blade
manufacturers and distributors but also GRP pipe manufacturers utilizing filament winding
method.
Temelsan as being family owned company and established in 1976 started the business with the
production of vertical bandsaw machines which are used for accurate and mass production
cutting in the business fields such as automotive, aerospace, household-related, etc.
Our own products
Block/Plate Cutting Vertical Bandsaw Machine: DK-3500
Vertical Bandsaw Machines: DK-400 series, DK-600 series, DK-900 series, DK-1100, DK-1500,
DK-2000, DK-3500
Flash butt Welding Machines, KN 41 HBS , KN 67 HBS, KN 67 HBA, KN 100 HBA and KN 100 PLC
Horizontal Bandsaw Machines: CUT-300 STO
Resistance Welders used on Vertical Bandsaw Machines: MD-02 and MD-03
Grinder (used to grind the flash on the bandsaw blade after being welded): TAS-10001-RT / SL
Shear Cutter (used to cut the tips of bandsaw blades to prepare for welding): MAK-01, MAK-01
HP (manual and hydrau-pneumatic types)

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
2. CONDITIONS OF OPERATION
In order to run the machine here is the electrical requirements,
Phase-Neutr: 240 V 50 Hz
Phase-Phase: 400 V 50 Hz
Attent that all the doors are closed while the machine is running.
3. SAFETY STIPULATIONS
Never do maintenance and repair work when the machine is energized.
Never step over the cables and the equipments.
Never remove or replace the covers with the non-standardized one of electrical
motors, fans, moving parts.
Never come close to the machine and never perform any action till all the moving
parts of the machine stop completely.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
4. SAFETY SIGNS ON THE MACHINE AND THEIR MEANINGS
ATTENTION! LIVE ELECTRICITY
ATTENTION! DANGER

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
5. GENERAL DESCRIPTION OF THE MACHINE
5.1. Description of the Machine
VERTICAL BANDSAW MACHINE DK 1500 LS
5.2. Expansion of the Model Name
DK-X00. 0X (S1)
DK : VERTICAL BANDSAW MACHINE
X00 : Throat width (distance between the vertical frame and the bandsaw blade
0X : Sub-model of the actual model
(S1) : CE certified (Some models without S1 designation might have CE certification whereas the ones
with S1 designation certainly have.)
5.3. List of Machine Models
The machines are classified according to the throat width and the types of accessories equipped
as standard and produced:
DK-400 ÖZEL DK-400. 01/EXPORT DK-400. 01 DK-400. 01 S1
DK-400. 02 DK-400. 03 DK-400. 03 S1 DK-400. 04
DK-400. 05 DK-400. 05 S1 DK-400. 08 DK-600 ÖZEL
DK-600. 01 DK-600. 02 DK-600. 03 DK-900 ÖZEL
DK-900. 03 DK-1100 DK-2000 DK-3500
The machines with CE certification are listed below:
DK-400. 01 S1 DK-400. 03 S1 DK-400. 05 S1 DK-400. 08
DK-600. 03 DK-900. 03 DK-1500 DK-3500

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
5.4. Machine type and Specifications
5.4.1. Machine type: DK-1500-LS
5.4.2. Machine specifications
Main Motor
7,5 kW
Dimension of Table
800 x 1500 mm
Cutting Height Over Table
1200 mm
Throat Width
800 mm
Cutting Speed
2-1000 mm/min
Servo Travel Stroke
1500 mm
Equipment Configuration Providing the Speed Adjustment
Frequency Invertor
/ PLC
Length of applicable bandsaw blade
6850 mm
Width and wall-thickness of applicable bandsaw blade
54x1,3 / 54x1,6 mm
Height of the table from the ground
910 mm
Weight of the machine
7000

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
6. Sample of Machine Name Plate

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
7. GENERAL PRINCIPLE OF OPERATION
Field of Application : Used for cutting all kinds of metals in straight or curve-form.
Principle of operation : The machine will be operated by one personnel only. The operatör
places the metal workpiece on the table of the machine and fixes it with the vise(s). Turns the
machine ON from the main switch. By pressing the GREEN button, initializes the rotation of
bandsaw blade. Adjusts the speed of rotation noticing the type and the hardness of the
workpiece. If the machine is equipped with a hydraulic table, then the speed of the hydraulic
table must also be adjusted according to the type and the hardness of the part to be cut. The
operatör can start cutting.
Attention! The operator must stand at the point shown as (X) below when the machine runs.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
8. PREREQUISITS OF TRANSPORTATION
8.1. Transportation style
VERTICAL BANDSAW MACHINE is monolithic during the transportation.
8.2. Precautions
•The machine can only be lifted by using proper rope hung on the head of the
machine itself.
8.3. Conditions for transportation
The notices of transportations are listed below:
a) Placing the machine on the transporting vehicle firmly and tightened with ropes to
eliminate possible bending and vibration during the journey.
b) The height of the tunnels and the bridges along the travelling route must be taken into
account. It is very important especially for DK-3500 and above.
8.4. Storing Conditions
a) Roof of the storing area must be closed.
b) There must not be any contact with moisture/water around, on top or under the machine.
c) It must be prohibited for unauthorized personnel to come across/intervene with the
machine
d) There must be no risk of fire in the area to be stored.
After connecting the electrical cables, authorized an experienced personnel will make the
necessary adjustments and commission the machine.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
9. INSTALLATION AND OPERATIONAL INSTRUCTIONS
9.1. UNLOADING
Machine should be carried as below drawing. Customer is fully responsible to provide
necessary ropes.
Please check the rope hanging at below drawing.
Please remove both upper covers before you carry machine.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
9.2. INSTALLATION
Placing the machine to the final installation area will be done by the customer itself.
The customer is fully responsible of the accidents caused by imporper lifting, carrying and
placing the machine to the installation area.
Installation, Setup, Commissioning and Initial Operation is under the responsibility of the
customer except DK-3500. All the machines except DK-3500 are monolithic and need the
electrical connection only.
If the electrical connections is done by unauthorized personnel the warranty voids immediately
and the manufacturer will not be responsible of any circumstances.
The customer is responsible to provide the cables to be connected to the electrical panel of the
machine.
To provide the cables to the electrical cabinet and to provide electricity are under customer’s
responsibility.
Electrical connections must be done by qualified electricians only.
The manufacturer will not be responsible if unauthorized and unexperienced electrical
technician intervenes the machine.
The customer has the right to claim an authorized personnel from the manufacturer to
check what has been done. Then the customer has to pay for the costs of international flight
tickets, hotel accommodation, food and beverage, etc. for 2 personnel from the
manufacturer.
Make sure that there is no obstacle around/on/in the machine.
1. Connect 5x4 TTR type of cables to the power terminals in the electrical panel of the
machine.
Attention! The machine must be grounded by a yellow-green colored cable.
2. Turn the main switch on. Press the green button controlling the main motor. Now the
speed control is possible. Press plus-minus signed buttons next to the speed control
equipment to change the speed of rotation of the bandsaw blade.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
NOTE: If the main motor is running in opposite direction then 2 phases of the electrical
connections must be interchanged to gain the correct direction of rotation. If any of
those doors of the machine is open then the machine will not run. Besides, if the
bandsaw blade is not tightened to a certain level, the sensor switch of the bandsaw
blade breakage will block the machine as if the bandsaw blade is broken.
3. Now check the direction of rotation of the hydraulic motor. Check if it rotates in the
direction of the arrow sign located on the motor itself.
4. Before replacing the bandsaw blade; open the 3 of those covers in front side of the
machine and loosen the bandsaw blade tightening shaft. By pulling the loosened
bandsaw blade towards yourself, let it free from the wheels and the guides.
To install a new bandsaw blade, follow the procedure in reverse direction and apply
tightening pressure.
ATTENTION! Before replacement of the bandsaw blade turn the machine off from the
main switch.
While installing the new bandsaw blade notice that the teeth form should be towards
yourself.
The bandsaw blade might elongate due to the heat emission during running; check the bandsaw
blade, tighten it if necessary.
5. Depending on the diameter and the height of the workpiece adjust the upper bearing of
the bandsaw blade (the one next to the rack) to prevent collision with the workpiece
during running and fix the handle.
ATTENTION!: The more close the upper bearing mechanism is to the workpiece the
more sharp, perpendicular and smooth the cutting will be.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
9.3. OPERATIONAL INSTRUCTIONS
9.3.1. Operation of the Machine
It is completely under the responsibility of the customer itself. On the other hand if the
customer contacts the manufacturer for some advice, the manufacturer will support the
customer.
Check the Appendix 1 to know about the control panel of the machine.
Steps of the operation
1) Depending of the height of workpiece adjust the inserts to the closest location to the
workpiece.
2) Choose the right teeth form for the bandsaw blade which will be used to cut the
workpiece.
3) Adjust the rotational speed and the speed of the Servo controlled table according to the
workpiece to be cut.
4) At each bandsaw blade replacement, make sure that the bandsaw blade bearings and
the inserts touch parallel to the workpiece. This should be done for the one at the lower
wheel.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
10. TRAINING
Training at the manufacturer’s site will be free of charge. If requested at the buyer’s site then the
flight tickets, hotel accommodation, food and beverage costs for 2 persons from the
manufacturer will be paid by the buyer. If an unauthorized personnel deal with the machine the
warranty voids immediatley.
11. SPARE PART LIST
MECHANICAL AND ELECTRICAL SPARE PART LIST
DESIGNATION
TYPE
Q’TY
1
MAIN MOTOR
ELECTRICAL
1
2
HYDRAULIC MOTOR
ELECTRICAL
1
3
BANDSAW INSERTS
STEEL
2
4
FREE WHEEL
CAST IRON
1
5
UPPER WHEEL
CAST IRON
1
6
WHEEL OF GEAR
CAST IRON
1
7
SERVO MOTOR
ELECTRICAL
1
8
SERVO GEARBOX
MECHANIC
1
9
HYDRAULIC TENTION UNIT
MECHANIC
1
10
CONTROL MONITOR
ELECTRONIC
1
12. SERVICE
The necessary parts will be distributed by the manufacturer once the buyer claims during repair
work or maintenance.
During warranty period at any circumstances where the unauthorized personnel use the
machine the warranty will void immediately.
The warranty is a limited warranty and covers the spare parts only. If the buyer claims service
from the manufacturer then the service cost, flight tickets, hotel accommodation, food and
beverage costs for 2 persons will be paid by the buyer.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
13. PLANNED MAINTENANCE CHART
13.1. DAILY MAINTENANCE
a) Open all the covers and clean all the parts inside with an air gun.
b) During down-times, the bandsaw blade should be loose; untighten it.
c) Clean up the chips on those of 3 wheels every day.
13.2. WEEKLY MAINTENANCE
Inspect the guides of blade. Replace it if necessary.
13.3. MONTHLY MAINTENANCE
a) Check the level of lubricant of hydraulic system. If the level is not full then add the
lubricant.
b) Check the valves. If oil is leaking replace them.
c) Lubricate the bandsaw blade tensioning unit.
d) Rack-shaft should be lubricated.
13.4. BI-ANNUAL MAINTENANCE
The initial oil of gear should be replaced after 300 hours of operation. Then replace the oil of the
gear bi-annually. The oil no. is 140.
14. TROUBLESHOOTING
To gain optimal performance is only possible to have an optimal combination of bandsaw blade
and bandsaw machine. The main sources of the problems confronted are; wrong feeding force,
wrong saw speed, wrong coolant concentration, wrong teeth form and improper repair work
done.

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
Problem
Probable Cause
Solution
•Incorrect blade
•Band tension too high
•Excessive feed
•Incorrect cutting fluid
•Wheel diameter too small
for blade being used
•Worn or chipped
pressure block (back-up
guide)
•Blade rubbing on wheel
flanges
•Teeth in contact with
work before starting saw
•Side guides too tight
•Teeth too coarse. Check your
cutting chart
•Reduce band tension. See
Machine Operator's Manual
•Reduce feed pressure
•Check your coolant
•Use thinner blade and lower
speed
•Check pressure block. Replace
if worn
•Adjust wheel alignment
•Allow 1/2" clearance before
starting cut
•See Machine Operator's
Manual
•Blade teeth inverted
(backwards)
•Improper break-in period
•Hard spots in material
(like scale)
•Material work hardened
(check for hardness and
adjust feed)
•Improper cutting fluid or
mixture
•Speed and feed too high
•Install blade correctly
•Reduce feeds and speeds
during break-in period in
accordance with
manufacturers'
recommendations
•Check material for actual
hardness - hard spots like
scale or flame cut surfaces
•Increase feed pressure
•Check your coolant
•Check your cutting chart
•Teeth dull
•Over or under feed
•Improper pitch blade
•Cutting fluid not applied
evenly
•Incorrect blade (too
many teeth per inch)
•Guides worn or loose
•Use new blade
•Check your cutting chart
•Check your cutting chart
•Adjust coolant nozzles
•Check your cutting chart
•Tighten or replace guides

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE
TEL: [phone] FAX: [phone] www.temelsan.com [e-mail]
•Over feed
•Lack of band tension
•Tooth set damage
•Loose guide arms or set
too far from work
•Check your cutting chart *
•Check Operator's Manual for
correct tension
•Check material hardness
•Adjust arm as close to work as
possible - tighten and align.
Check guide
•Improper or lack of
cutting fluid
•Wrong coolant
•Excessive speed or
pressure
•Incorrect blade (wrong
pitch)
•Check your coolant
•Check your coolant
•Reduce speed or pressure.
Check your cutting chart *
•Check your coolant
•Incorrect feed and/or
speed
•Incorrect blade (wrong
pitch)
•Saw guides not adjusted
properly
•Check your cutting chart
•Check your cutting chart
•Adjust or replace saw guides
•Indexing out of sequence
•Material loose in vise
•Check for correct indexing
sequence (head rise)
•Check hydraulic pressure
•Feed pressure too high
•Tooth lodged in cut
•No cutting fluid or incorrect
coolant
•Hard spots, scale,
inclusions, etc.
•Incorrect blade (wrong
pitch)
•Work spinning in vise; loose
"nest" or bundles
•Reduce feed pressure and/or
speed. See your cutting chart
•Never enter same (old blade), cut
with new blade
•Check your coolant
•Check hardness. Descale and/or
anneal if necessary
•Check your cutting chart
•Check hydraulic pressure; be
sure work is firmly held