woodmizer DSBA-40 Manual instruction

Wood-Mizer®
FOUR-SIDED PLANING MACHINE
Safety, Setup, Operation
& Maintenance Manual
DSBA-40 rev. A1.00
Safety is our #1 concern! Read and understand
all safety information and instructions before oper-
ating, setting up or maintaining this machine.
Form #995
!

Table of Contents Section-Page
2 doc030910 Table of Contents
SECTION 1 INTRODUCTION 1-1
SECTION 2 GENERAL INFORMATION 2-1
2.1 Application of the product......................................................................................... 2-1
2.2 Brief description of the product................................................................................. 2-1
2.3 Technical parameters of the machine ........................................................................ 2-2
2.4 Standard equipment .................................................................................................. 2-3
2.5 Special equipment ..................................................................................................... 2-4
2.6 Industrial Safety and Hygiene ................................................................................... 2-5
SECTION 3 PRELIMINARY OPERATIONS 3-1
3.1 Transport method....................................................................................................... 3-1
3.2 Foundation................................................................................................................. 3-2
3.3 Connecting the machine to the mains........................................................................ 3-3
3.4 Connecting the machine to the exhaust installation .................................................. 3-3
3.5 Working conditions ................................................................................................... 3-4
SECTION 3 CONTROLS 4-1
3.1 Setting, adjustment and control devices .................................................................... 4-1
SECTION 4 STARTING – A TRY 5-1
SECTION 5 WORKING ON THE MACHINE TOOL 6-1
5.1 Fixing and adjustment of cutters ............................................................................... 6-1
5.2 Fixing of moulding cutters ........................................................................................ 6-4
5.3 Adjustment of table shafts, feed rollers and pressure devices................................... 6-5
5.4 Table Adjustment and the operation of the Limit Switches...................................... 6-6
5.5 Machining.................................................................................................................. 6-8
SECTION 6 MAINTENANCE AND REPAIRS 7-1
6.1 Inspections and repairs .............................................................................................. 7-1
6.2 Lubrication instructions............................................................................................. 7-2
SECTION 7 LISTINGS 8-1
7.1 Roller bearings........................................................................................................... 8-1
7.2 List of V-belts............................................................................................................ 8-1
7.3 List of chains ............................................................................................................. 8-2
7.4 List of wear parts ...................................................................................................... 8-2
SECTION 8 TROUBLESHOOTING GUIDE 9-1
SECTION 9 BRAKING TIME ADJUSTMENT 10-1
SECTION 10 DATA ON NOISE 11-1
10.1 Admissible noise levels ........................................................................................... 11-1

Table of Contents Section-Page
Table of Contents doc030910 3
SECTION 11 SERVICE AND REPAIRS 12-1
SECTION 12 ADDITIONAL CLAMP ASSEMBLY – SPECIAL EQUIPMENT 13-1
SECTION 13 ELECTRICAL INFORMATION 14-1
13.1 Wiring diagram of main circuit ............................................................................... 14-1
13.2 Wiring diagram of control circuits .......................................................................... 14-2
13.3 Assembly diagram................................................................................................... 14-3
13.4 Electrical Equipment Layout................................................................................... 14-4
13.5 A list of electrical components................................................................................ 14-6
13.6 List of symbols used on the control panel............................................................... 14-8

INTRODUCTION
1
1-1 15doc030910 INTRODUCTION
SECTION 1 INTRODUCTION
The present documentation contains information that should be used when preparing the
machine for operation, working with it and when servicing or repairing it, as well.
1.High cutting speeds on wood working machines generate noise levels that exceed the admissi-
ble level NDN 85 dB. The producer requires that the operators use hearing protection and that
the moulder should be in a soundproof enclosure.
2.Since the machine tool is subject to constant changes improving its design the present docu-
mentation is solely assigned to the machine tool to which it has been attached according to its
serial number.
3.Starting the feed is only possible once the cutter shaft of the planing machine and heads are
switched on.
(In order to start the feed without starting the cutter heads, move the heads out to their maxi-
mum position on the limit switches)
4.In order to ensure safe and continuous trouble – free operation one should:
- Observe general and specific rules of Industrial Safety and Hygiene.
- Only use the machine when connected to a dust extraction system
- Observe the recommendations given in section ,,Maintenance and repairs’’
5. To achieve optimum results the moulder should be used with timber with a Moisture Content
lower than 18%. The recommended Moisture Content varies with the final use.
- Floor Boards 8-10 percent
- Furniture or construction woodwork for rooms with central heating
8-10 percent
- Furniture or construction timber for rooms with open fire heating
10-12 percent
- Construction woodwork exposed on one side to heated interior and to outdoor fresh air on
the other side 12-15 percent
- Wood construction under roof but not closed 15-17 percent
6.Any element to be machined should have at least one straight face (towards the guide).
7.Machining of elements whose curvature exceeds the maximum permitted machining allowance
is not admissible.
8.Before starting work, check the rotation direction of the cutter shafts, cutter heads and feed roll-
ers. The rotation direction of the tools must be opposite to the feed direction and the same as
the direction of the arrows located on the machine tool .

General information
Application of the product
General information 15doc030910 2-1
2
SECTION 2 GENERAL INFORMATION
2.1 Application of the product
The moulder is designed for use on wood or wood like materials, for planing, thicknessing and
moulding. Using the machine correctly will allow you to produce an excellent surface and a high
degree of accuracy.
With correct adjustments and correct tooling you can produce elements such as, skirting boards,
moulding, trim, window elements, parquet, etc.
2.2 Brief description of the product
The four- sided planing machine DSBA-40 is composed of three main machining groups:
- surfacing - machining an element from the bottom.
- thicknessing - machining using top and bottom planers.
- side moulding or planing - using the two vertical cutter heads.
Moreover, the machine tool is equipped with the following auxiliary devices:
- shifting device
- adjustment device for the edging table - top-bottom
- adjustment device for thicknessing table - top-bottom
- table rollers
- clamp device - shift rollers
- protection devices - anti-kick-back fingers, brakes, screen etc.
- exhaust fan - to be connected to the dust exhauster
- control devices – mechanical and electrical
All of above have been built on to a single solid steel frame to allow for easy access and main-
tenance.

General information
Technical parameters of the machine
2
2-2 15doc030910 General information
2.3 Technical parameters of the machine
Parameter Unit Dimen-
sion
Maximum cutting width
- one side without the setting guide*
- three side and four side with the setting guide
mm
mm
400
320
Minimum width for four-side cutting mm 40
Minimum thickness of machined element
- one side without the setting guide
- three-side and four-side with the setting guide
mm
mm
3
15
Maximum thickness of machined element
- one side without the setting guide
- three-side and four-side with the setting guide
mm
mm
170
100
Minimum length of machined element** mm 350
Maximum cutting allowance cutting
-from bottom on edging machine
-from top on the thicknesser
mm
mm
5
6
Feed speed m/s
[m/min]
0.1 ; 0.2
[6] ; 12]
Cutting speed of cutter shafts M/s ~ 29
Rotation speed of spindle tools Rota-
tions Min-
ute
r.p.m
~ 5000
Maximum diameter of spindle tools*** mm ø 160
Power of drive motors for the edging, thicknessing machines and verti-
cal heads
KW 4 x 4
Power of the feed motor KW 0.8 / 1.1
Power of lifting motor KW 0.75
Rated voltage V3x400
AC+PE
Rated frequency Hz 50
Rated power consumption KW 17

General information
Standard equipment
General information 15doc030910 2-3
2
* dismantling of heads on spindles is required
** in case of machining elements 350 up to 550 mm long one should apply an additional clamp
assembly (see special equipment)
*** resetting of rear guidelines (items 7 and 8 in Fig. 3, page 9) is needed.
2.4 Standard equipment
Rated current A 37
Insulation level I
Internal protection IP 54
Overall dimensions- length
- width
- width (the heads set at extremes)
- height
mm
mm
mm
mm
~ 3120
~1200
~ 1600
~ 1400
Weight of the machine Kg 1790
Sawdust - extraction pipe diameter mm 2x120
1x100
Air velocity m /s 20-24
Dust Collection air demand / h 3200-38
00
Name of element Drawing no
Dimension Qua
ntity
of
piec
es
Special spanner 17 1
Key to the cubicle GN 119.1 VDE 1
Planing knives (mounted on shafts) DNS JA a 410x35x3 PN/D-54700 8
Box Spanner RWPd 41 105x35x3 PN/D-54700 8
Crank for setting of spindles PN/M-65010 1
Bushes for moulding pins 1
M3

General information
Special equipment
2
2-4 15doc030910 General information
2.5 Special equipment
Special spanner 17 ø30/50x5
ø30/50x15
ø30/50x25
ø30/50x35
ø30/50x50
J255.01.07.05
2
2
2
2
2
2
Name of element Drawing No Quantity
Instrument for setting of cutters (for thiknesser) DUKB 1 set
Instrument for setting of cutter ( for edging machine) PUNA-3 1 set
Sub-assembly of extra clamp J327.20.01.00 1 set

General information
Industrial Safety and Hygiene
General information 15doc030910 2-5
2
2.6 Industrial Safety and Hygiene
In order to avoid dangerous situations when using the machine tool one should strictly observe
the following rules and instruction.
2.6.1 General requirements
a) The moulder must be used according to its application
b) The moulder should only be used by an operator trained in the use and maintenance and setting of the
moulder, or by an operator trained in its use provided that the moulder has been set up by a qual-
ified operator.
c) The operator should operate the moulder in accordance with Health and Safety regulations and with
the instructions contained in this manual. It is the duty of the operator to familiarise himself with the
contents of this manual.
d) Lighting should be at least 300 Lx.
e) On no account should guarding be removed while the machine is running.
f) The machine should be disconnected at the Master Switch before carrying out any maintenance,
inspection or satting up.
g) Cleaning of the machine should only be undertaken when the moulder is at a complete stop and iso-
lated
h) If the moulder is being operated by more than one person a communication system should be adhered
to.
i) Repairs and inspections should be carried out by a qualified and authorized person.
j) Braking the moulder by hand or using any other tool is strictly forbidden.
k) Do not check for surface finish or dimension while the moulder is in operation.
l) When machining long material adequate additional supports must be used.
m) The operator must:
- check that the tooling is in good condition and that all guards and safety devices are operational.
- inform authorised personnel if any faults are found
- only restart the machine after repair, setting or servicing
- use ear protection
n) Should material become ammed in the machine it is forbidden to push it or otherwise try to extract it
without first shutting off the moulder and lowering the table.
2.6.2 Detailed requirements
a) Before starting work, check the tightness of the cutters.
b) Whenever you leave the moulder disconnect it by using the Master Switch.
c) Avoid accumulation of material, shavings and waste near the working stand.
d) It is forbidden to machine material that comes from demolition in which foreign matter could be found.
e) Always lock the table at its operating height.
f) Provide the operators with ear protection.
g) You mustn’t use tools with rotation speeds lower than those attainable on the machine tool.
h) It is forbidden to stand in the way of possible throw-back of material being machined.
i) Work only when the dust collection system is connected.
j) In case cutter is replaced the insert number and the groove number on the shaft should be consistent.
k) It is forbidden to adjust rollers, pressure bars when the machine tool is running.
l) It is forbidden to operate the moulder without the anti kick-back fingers in place.
m) At least once a shift, check the operation of the anti kick-back fingers by carrying out the following
steps:

General information
Detailed requirements
2
2-6 15doc030910 General information
- Disconnect the moulder by use of Master Switch.
- Remove the upper guard
- Using a piece of wood, check that the fingers lift freely and descend under their own weight
- Visually check the condition of the finger edges - they must be sharp
- Set the table at, for instance, 30 mm
- Insert a piece of wood of 30 mm thickness
- Try to remove the piece of wood with a sudden backwards pull
You should not be able to withdraw the board.
- Replace the upper guard.

Preliminary operations
Transport method
Preliminary operations 15doc030910 3-1
3
SECTION 3 PRELIMINARY OPERATIONS
3.1 Transport method
It is recommended to use a fork-lift truck when transporting the machine tool.
Fig.1
Remarks
1) The machine tool to be transported should be completely maintained and provided with trans-
portation skid. Equipment elements should be packed in plastic bags.
2) After having transported the machine- tool and positioning it all the maintenance grease
should be removed from all unpainted surfaces. Inspect all parts and in case paint coating has
been damaged give it anti-corrosion protection.
Check if the following elements has been damaged or deformed:
-cutter shafts and their inserts, pressure screws, bearings and shaft housings.
-Electrical motors
-Material guideline
-Control buttons
The damaged elements should be replaced with new ones. After protective coating removal,
mount all dismounted for transportation reasons elements back on the machine tool.
fork-lift
Felt insert
j001

Preliminary operations
Foundation
3
3-2 15doc030910 Preliminary operations
3.2 Foundation
The machine must be set up on a previously prepared concrete foundation minimum B20 grade.
The dimensions that you need to prepare the foundation are shown in Figure 2.
Before securing the machine to the foundation, perform the following steps:
a) Remove the transportation skid,
b) Insert M12 x 120 foundation bolts through the holes in the machine body,
c) Place the machine on the foundation,
d) Reinstall all elements removed previously for transportation reasons,
e) Level the machine within the accuracy of 0.1 mm to 1 mm in two rectangular directions by
putting a level on the tables.
After performing the above steps, fasten the machine to the foundation.
Fig.2
Notice:
Application of anti vibration insulators when fixing the machine on the foundation has a positive
effect on the wear and tear of cutter shaft bearing nest and vertical spindles as well as on the
noise emission.
100
100
750
100
640
150
180 920
540
1280
1050
180
250
Entry hole for the main supply
j002

Preliminary operations
Connecting the machine to the mains
Preliminary operations 15doc030910 3-3
3
3.3 Connecting the machine to the mains
The electrical installation is adopted to the supply Line TN-S (L1, L2, L3, PE). In case of four-lead
supply line the connecting should be carried out respecting all valid regulations. The electrical
equipment has no main protection. Such a protection should be made on the supply line using
installation disconnectors of category C-35A. The machine tool should be fed with a cable OPd 5
x 6 mm2.
Before connecting the machine tool to the mains one has to check the technical condition. If the
resistance is lower than 0.5 M Ωm one has to dry all the equipment.
You must not connect the machine tool to the mains without having measured, previously, the
insulation condition of the equipment. A protection network system should be provided according
to the regulations in force.
The whole wiring system as well as the motors will function correctly if the supply voltage is not
below 95 percent or higher than 110 percent of its nominal value.
The entry of the feeding cable is shown in the drawing presenting the foundation.
The length of cable ending allowance for connection should be about 1 m. The leads of feeding
cable should be connected to appropriate terminals.
3.4 Connecting the machine to the exhaust installation
Before connecting the machine to the plant exhaust system one should check if the system satis-
fies the conditions started in Section1..
After having inspected the system one should connect the machine tool to connector pipes using
a flexible hose ?120.
Place the hose on the connector pipe and fix it with a pressure band.
Notice !
1.It is forbidden to connect the machine to the shaving exhaust system to which electrical, weld-
ing or other devices that can generate sparks have already been connected.
2.It is forbidden to work on the machine tool without having connected the exhaust system- you
risk losing the warranty when not observing that regulation.

Preliminary operations
Working conditions
3
3-4 15doc030910 Preliminary operations
3.5 Working conditions
In order to ensure a failure free operation of all units of the machine tool one has to respect the
following building conditions:
1) Kind of the room – closed with possible sound insulation screens being installed, minimum 3 m
high, with the possibility of connecting dust exhaust system.
2)Temperature – the machine tool should operate in a room where the temperature stays within
the range of + 5oC to +35oC.
3) Humidity- the maximal humidity in the room should not exceed 85 percent.
4) Lighting at the work stand – minimum 300 Lx.
5) One shift work – 8 working hours.

Controls
Setting, adjustment and control devices
Controls 15doc030910 3-1
3
SECTION 3 CONTROLS
3.1 Setting, adjustment and control devices
1,2 Cutter Head shields
3 Clamp assembly
4I, 4 II Guide – adjustable
5, 6 Clamp element
7,8 Rear guides
9 Horizontal guide
10, 11 Adjustment screws for the width of 3-side machining
12 Screws for vertical adjustment
13, 14 Adjustment screws for V-belt tension
15 Lead in for setting bar-side of the table
16 Screw for adjustment of the guide on the thicknesser’s table
17 Screw for adjustment of the guide on the edging machine table
18 Locking screw for the setting of edging machine table.
19, 20 Adjustment screw for setting of rear guides
21 Hand wheel for lifting/lowering of the table
23 MASTER SWITCH
24 On button for the edging machine
25 On button for the thicknesser.
26 Off button for the edging and thicknessing machine
27 Edging machine and thicknesser brake release switch (access to the switch is possible-
only after opening the upper cover)
29 Signal lamp indicating the machine being switched on
30 EMERGENCY STOP disconnects all the motors
31 On button to lift the table
32 On button to lower the table
33 On button for the left head
34 On button for the right head
35 Off button for the left and right heads
36 Off button for the feed
37 On button for the feed at Speed I
38 On button for the feed at Speed II

Controls
Setting, adjustment and control devices
3
3-2 15doc030910 Controls
Fig.3
Fig.4
16 4I
6
1
20
7
3
10 12 16 17
4II
17 15
18
21
951211
8
19
2
Side view of the table from the top
(
without cover or clamp rollers
)
j003
27
24 25 26 29 30
31 32
33 3435
3637 38
23
DSBA-40
12 L R
View of the button plate

Starting – a try
Starting – a try 15doc030910 4-1
4
SECTION 4 STARTING – A TRY
After studying the manual and the operation of the moulder we can start the moulder as follows
1. Check that the cutter heads and knives are firmly and corretly in place
2. Check that all guards are in place
3. Check that the pressure rollers and guides are correctly aligned
4. Switch the Master Switch ON
5. Check the rotation direction of the cutting heads and feed rollers by starting each operation
individually (The rotation direction of the tools must be opposite to the feed direction and the
same as the direction of the arrows located on the machine tool.).
6. If the rotations is incorrect, isolate the moulder by use of the Master Switch and change
phases on the supply terminals
7. Once all the heads and feed are operating correctly, start all the functions and leave the
moulder to run for about one hour without and load
8. While the moulder is running check for any noise or vibration that may indicate a possible fail-
ure
9. Stop the moulder and check the bearing temperatures. They should not exceed ambient
+50 C.
10. Check for any loosening or misalignment and adjust as necessary
After performing all of the above checks and operations you may now start to use the moulder.
°

Working on the machine tool
Fixing and adjustment of cutters
5
5-1 15doc030910 Working on the machine tool
SECTION 5 WORKING ON THE MACHINE TOOL
5.1 Fixing and adjustment of cutters
The cutter head is designed to allow the use of planer blades with the dimensions 3mm x 35mm
x 410mm according to PN/D-54700. The planer blades are locked in place by tightening the
screws that press the wedge shaped bar against the planer blade. The whole assembly is
dinamically balanced. The planer knives should be straight and correctly sharpened (blade angle
should be 400 +/-2 degrees) and the length and thickness deviation should not exceed
+/-0.5mm. If these requirements are not met the balance of the assembly will be upset causing
excessive vibration, bearing wear and the risk of material being thrown back.
The knives set 1.1mm above the cutter head should be tightened using the tool provided (see
section 1.4) Extending the handle or hammering the handle is not permissible.
The planer knives must be less than 25 mm wide
The factory set for the planer knives is 1.1mm above the cutter head. To ensure ensure accurate
and trouble-free planing the deviation should not be more than +/-0.02mm.
To adjust the planing knives use the special tool provided - Section 1.5, Special Equipment
Tool DUKB for cutter adjustment ( relates to the thicknesser)
The tool DUKB is used in the knife adjustment on the thicknesser shaft with planing knives with
the nominal diameter of 122 mm.
Adjustment procedure
1. Set the indicator to zero using the check gauge
2. Insert the knife into a groove of the cutter shaft to about 1.5 mm of height and tighten lightly
the two outside pressure screws.
3. The instrument set to zero should be put onto the cutter shaft
4. Strike the knife with a wooden block and lower the knife to 1.1 mm (read the distance on the
indicator).
5. Repeat the procedure in three positions: middle, left and right (check the knife clearance
1.1mm)
6. Tighten carefully all screws starting from the middle to the left and right
7. Similarly, adjust the remaining knives.
300701

Working on the machine tool
Fixing and adjustment of cutters
Working on the machine tool 15doc030910 5-2
5
Fig.5
Note:
After having finished the adjustment you have to check the tightening of all screws – otherwise
you risk an accident.
122
1,1
clamping screw
sensor base
screw fixing the indicator
check gauge
flat tip of the indicato
r
dial indicator
j005

Working on the machine tool
Fixing and adjustment of cutters
5
5-3 15doc030910 Working on the machine tool
Instrument PUNA- 3 (for edging machine) for cutter adjustment.
Fig.6
The correct setting of knives (B) in the cutter shaft determines the correct operation of the
machine tool. The operation is possible by use of the instrument PUNA- 3.
Preparation procedure
The instrument with dial indicator (3) fixed in handle (4) is put on a flat surface (for instance,
laying out plate or edging machine table). The foot of indictor should be level with the edge of
self-aligning plate (2). We fix that position by turning the external scaled ring to the value ‘’0’’. The
instrument thus prepared is ready to serve as a base for adjustment of knives (B) in the cutter
shaft (A).
Adjustment procedure
The instrument should be placed on the outfeed table of the edging machine which is the refer-
ence base. Shifting the instrument move plate (2) on the set knife (B) so that it sits on it.
Turning cutter shaft (A) to the left and right the knife edge will move on the pate (2) edge causing
the indicator (3) pointer to deflect.
Adjust the knife excess so that dial indicator (3) points finally to the value ‘’0’’. After having
checked the knife’s excess at three points (at two extremes and in the middle) and confirmed the
correct setting we tighten all screws (C) and start adjustment of the next knife.
B
C
D
A
2
4
3
1
receiving
table
1 - base
2 - small plate
3 - dial indicator
4 - indicator grip
A - cutter shaft
B - knife
C - screw
D - spring
j006