HYDRAULIC GUILLOTINE SHEAR CONTENTS - Contents - Introduction - Guarantee document - Declaration of conformity - Final control report –3
PAGES -
A – DELIVERY INFORMATION 1.1 – Technical characteristics 2.1 – Introduction of the machine 3.1 – Standard equipment 3.2 – Requested equipment
1 2-3 3 3
B – MACHINE AND PERSON SECURITY 1.1 – Information for hydraulic oil 1.2 – Fire data 1.3 – Stroge and reactivity data 1.4 – Recommended first aid in case of contact with hydraulic oil 2.1 – Protection of hand and body 3.1 – Protection sheets montage measure 4.1 – Information for hydraulic machines 5.1 – Noise 5.2 – Noise level measurement 6.1 – Security procedure 7.1 – Security covers and switches 7.2 – Rest hazarda 8.1 – Introduction and safety labels put onto the machine
4 4 5 5 5 6 6 7 7 8 9 – 10 11 12 - 14
C – GUIDANCE NOTES FOR PLANT INSTALLATION 1.1 – Introduction 2.1 – Machine reception 3.1 – Machine transport 4.1 – Operation area of the machine 5.1 – Pre-start up details 6.1 – Electrical connections 7.1 – Direction of motor 7.2 – Motor current information
15 15 15 - 16 17 17 18 18 18
D – STORING CONDITIONS
DURMAZLAR
19
SB
E – MECHANICAL ADJUSTMENT 1.1 – Cutting gap adjustment 1.2 – Table of cutting gap between the blades 2.1 – Blade adjustment 3.1 – Back gauge adjustment 3.2 – Parallelism adjustment of the backgauge support 3.3 – Backward turndevice of the support 4.1 – Tightening adjustment of the backgauge belt 5.1 – Balance surface 6.1 – Pay attention to following by cutting action
20 20 21 - 22 22 23 24 24 24 25
F – MECHANICAL MAINTENANCE 1.1 – Lubrication diagram 1.2 – Oil level display of the hydraulic tank 2.1 – Maintanance of the machine 2.2 – Maintanance of the hydraulic unit 3.1 – Probable defects to occur -
26 27 27 27 28
Operation of machine Setting plan Hydraulic schema Electric information form Electric schema Auxiliary documents
DURMAZLAR
-
SB
INTRODUCTION We as DURMAZLAR MAKINA have prepared this manual to give our customers information on maintenance, repair and technical data. Our first aim is to have the machine work in the maximum performance and to achieve this we use the best quality material , lastest technology and engineers to apply the material and technology to our production. Working expenses can be decreased by giving great attention to the period maintenance (accordly to the information on the following pages ) which in the case of applying it correctly the machine will work in a long time. Press Brakes one used for bending the different size sheets , Shears one used for different metarial which is suitable thickness ( sheet , Al , Cu , plastic , paper , etc. ) in our product range. As it is the owners responsibility to read the manual it should also be read a least once by the operators who works on the machine. The manual should be next to the machine so you can be prepared to fix any breakdowns that may occur. Our company has the right to make any new technology changes to the machines without consulting any authority. We have been selling to the domestic market since the year of 1956 and for the last 15 years we have an overseas market which has taken us on a higher level. Therefore we have reflected to our customers the markets exprience and new technology. We hope that the machine will be beneficial for you and your work.
DURMAZLAR MAKINA SAN. Ve TIC. A.S. Organize Sanayi Bölgesi 75. Yıl Caddesi BURSA Tel : + 90 224 241 80 00 pbx. Fax : + 90 224 242 75 80 – 242 93 73 Internet : www.durmazlar.com.tr e-mail :
[email protected] [email protected]
DURMAZLAR
SB
:
SIGNITURE & STAMP
: DURMA
: SB 3006
: 6076074645
TRADEMARK
MODEL
SERIAL NO
:
:
:
:
:
TITLE
ADRESS
TELEPHONE
DATE OF SALE
SIGNITURE AND STAMP
SELLER COMPANY
: HYDRAULIC GUILLOTINE SHEARS
TYPE
PRODUCT
: 20.12.2006
: ( 224 ) 242 75 80
FAX
DELIVERY TIME
: ( 224 ) 241 80 00
TELEPHONE
: 160227
: ORG. SAN. BÖL. 75. YIL BULVARI NİLÜFER / BURSA
ADRESS
INDUST.REGISTER NO
: DURMAZLAR MAK. SAN. VE TİC. A.Ş.
TITLE
MANUFACTORING COMPANY
Machine will be excluded from the guarantee scope.
8 – When machine's power supply is carried out apart from the data shown in the catalogue
(Add 1)
7 – Defects which may result from external physical strokes.
for St 42 kg/mm² .
6 –Not giving cutting clearance ( the cutting clearance is given according to max. 2 mm plate
5 – In case of operation over the maximum operation pressures as indicated in the catalogue.
4 – Dislubrication of the lubrication parts shown in the catalogue.
3 – The unfixation of it with anchorage bolts.
2 – Actuation of machine without being balanced
periodically.
1 – Pieces such as the air filtre and oil filtre which possesses necessity to be replaced
FROM THE WARRANTY
BELLOW MENTIONED PARTICULARITIES ARE EXCLUDED
warranty starling from the replacement date.
3 – A piece which is replaced in the validity of our guarantee possesses a 1 year
2 –The period of warranty starts from the date of delivery and it's validity is 1 year.
1 – All parts (excluding electrical parts) of the product are under the warranty of our firm.
WARRANTY CONDITIONS
DECLARACION DE CONFORMIDAD
Nosotros : DURMAZLAR MAKİNA SAN. TİC. A.Ş. Organize Sanayi Bölgesi 75. Yıl Caddesi Minareliçavuş BURSA / TURKEY Confirmamos completamente bajo nuestra responsabilidad, que el producto: NOMBRE MÁQUINA MODELO Nº DE SERIE
: 3100 x 6 mm. CIZALLA GUILLOTINA HIDRAULICA : SB 3006 : 6076074645
Para la que se emite esta declaración, cumple con las siguientes directivas; Directiva máquinas Directiva bajo voltaje
Directiva EMC
: 98 / 37 / EC ; : 73 / 23 / EEC ; : 89 / 336 / EEC ;
Este modelo de máquinas han sido examinadas por el; Entidad notificada nº : 0344 , Kema Registered Quality B.V.
Firmado en BURSA el 20.12.2006 Departamento técnico Mesut BAŞ
FINAL CONTROL REPORT - 3 -
PREPARED:
Hüseyin BÜLBÜL
APPROVAL:
Mustafa YÜCEL
VALIDITY DATE
: 24.06.1998
REVISION NO : 0 REVISION DATE.
: -
PAGE
: 1/2
TYPE : HYDRAULIC GUILLOTINE SHEAR ( CE’Lİ )
TYPE MACHINE NO
: .................SB 3006............... : .............6076074645.............
FIRM : ..................DURMAZLAR.......................
YEAR OF MANUFACTURING STROKE DEPARTMENT
: ..................FINAL MONTAJ........................
TEST
O.K.
1.0
Hydraulıc cylınders ; manuel Bearıngs ( space , tolerance , free movement )
ν
1.1
Hydraulıc cylınder speed control
ν
1.2
Overload safety
ν
1.3
Top & bottom blades adjust control
ν
2.0
Movement applıance ( connectıng rod , set of wheel , rods , spındles , Elbowcrank , pullıng bar , cardan joınt )
ν
2.1
[ space , tolarence , fluctuatıon , flang, Connectıng rod bearıngs ( ınterıor & exterıor ) spıked rıng ball bearıng Cover , crank rod pın eccentrıc pınworkıng shaft, Mıddle pın , gear wheels , eccentrıc bearıng , elbow Joınt , spındles , nut wedged shaft , flang joınt )
ν
2.2
Transferrıng gear system movement belts, Couplıng , gears
ν
3.0
Leakproof of movıng parts
ν
3.1
Frıctıon bearıngs ( wear lubrıcatıon )
ν
3.2
Sprıngs
ν
3.3
Settlıng and stabılızatıon on axle
ν
3.4
Ended fıxıatıon ( stroke )
ν
4.0
Frıctıon brake ( wear lubrıcatıon )
ν
4.1
Others accordıng to brake types A - pneumatıc : leakproof B - hydraulıc : leakproof C - dog brake : ( sıx edged nut , tıghtnıng collet, Dog , vulkollan collet ) D - sub contractors part – control
ν
5.0
Remote's movement ( shock-proof washer , gear Belts , gear chaıns , gears , chaın gears )
ν
DATE .20./.12./.06.
F300.50
: ......................2007........................ : .......................105.........................
CONTROLLED BY
Shortly wrıtten from of Trıal help and measure ment Data whıch may be essentıal
PRESPONSIBLE OF FINAL HYD.MEC. CONTROLS
SIGNATURE-STAMP
ELECTRIC
NAME - SURNAME G. SERBEST
MECHANIC–HYDRAULIK
S. GOKBAYRAK
954
400
NAME- SURNAME
SIGNATURE-STAMP
V. SAVAS
950 REV.0
FINAL CONTROL REPORT - 3 -
PREPARED:
Hüseyin BÜLBÜL
APPROVAL:
Mustafa YÜCEL
VALIDITY DATE
: 24.06.1998
REVISION NO : 0 REVISION DATE.
: -
PAGE
: 2/2
TYPE : HYDRAULIC GUILLOTINE SHEAR ( CE’Lİ )
5.1
Mechanıc parts : couplıng arm applıance , two hand Couplıng
ν
5.2
Electrıcal parts : ( cam relay protector , remote Cylınders , remote collectors , cırcuıt breaker Contact collet cable ınstallatıon koaxıal arm , Control panel end cırcuıt breake , lıght barer , Conformıty of foot pedal functıon etc. )
ν
5.3
Isolatıon test of motor at 1000 v tensıon rm: 1 mohm Cable ınsulatıon test at 500 v dc tensıon rk: 1 mohm
ν
Voltage decrease at earthıng lınes at end poınts u 1.5 v
5.4
Hydraulıc : ( slıdes , storer , manometer pump , pressure Increases & leak proof )
ν
6.0
Hydraulıc : ( ın general )
ν
7.0
Lubrıcatıon : ( adjustment , leakproof , check-up fıltre , oılıng Substances , scraper pump , scatterer )
ν
8.0
Safety applıance accordıng to uvv 11-062 norms Sınce 01.04 75
ν
8.1
Movıng conceal protectıon : ( functıon check-up )
ν
9.0
An extra arrangements : ( supplyıng bendıng system , swıtch adjustment )
ν
10.0 Comments :
DATE .20./.12./.06.
F300.50
CONTROLLED BY
PRESPONSIBLE OF FINAL HYD.MEC. CONTROLS
SIGNATURE-STAMP
ELECTRIC
NAME - SURNAME G. SERBEST
MECHANIC–HYDRAULIK
S. GOKBAYRAK
954
400
NAME- SURNAME
SIGNATURE-STAMP
V. SAVAS
950 REV.0
Pre Delivery Test Routines (Shears/Makas) Inspection for damage, if found submit separate report - Absent Received with all options and accessories (note on service report where they are located) Cosmolene removed- if sold locally protective cosmolene to be removed and machined surfaces and fasteners coated with rust inhibitor; if shipping out of state, leave cosmolene on machine (if removed coat with lighter protectant) Check and verify hydraulic oil is at proper level – Without oil Rust removed Touch up paint where needed (all scratches) Mount and check squaring arm and support arms. Check measuring scale calibration to the cut end of blade (note on service report where they are located) Check for foot pedal (note on service report where they are located) Straight and neatly apply all necessary safety signs Remove manual, applications software and parameters for office (both disc and written) All hydraulic, electrical, and mechanical schematics and parameters in manual All necessary accessories with machine Connectors checked for tightness (encoders, limit switches, hydraulic fittings, electrical wires, exterior fasteners, bolts for cylinders etc.) Put loc-tight on all sheet support rollers (if applicable) All measuring scales and markings in inch and in English All machine nameplates in English and marked accurate (check amps against manual electrical information) All limit switches set to proper location Fasteners for all sheet metal covers checked for tightness and appropriate Loctite applied Check blade clearance at min. and max. end to end, and set at factory specifications •_5 mm – 1040 mm_ Back gauge parallel and calibrated against lower blade Back gauge positioned 20 times the full range of travel Check back gauge between slots if equipped with sheet support option Check sheet support pillow block bearings Check the alignment of the back gauge belt to the pulleys Shear material full length and check blade for nicks or chips Machine to run for one hour All modes of operation working correctly Voltage set to customer requirement __400V__ Machine clean and clear of dirt, fingerprints etc. Apply rust protector to machine (according to shipment or storage) Wrap machine for delivery to customer, or if staying in storage cover with plastic Machines are to be checked and prepared carefully and completely so that they are ready to power up and run parts upon arrival to customers. Factory comments: ________________________________________________________________________________ ________________________________________________________________________________________________ Machine:________SB 3006________Serial:_________6076074645__________Controller:_______ENC 100________ Technician Signature:_____________Cabit ÖZKAN_________________Date:____________18.12.2006___________
A – DELIVERY INFORMATION A – 1.1 TECHNICAL CHARACTERISTICS
L
H
D
A
W
Cutting Length
Cutting Angle ( fixed )
Stroke per min.
Number of Holddowns
Holddown Force
Motor Power
Oil Capacity
Stroke
Throat Depth
Height
Length
Width
Total Width
Weight
TYP
Cutting Capacity
F
mm
mm
<
1/min
Pcs.
ton
kw
lt
mm
mm
mm
mm
mm
mm
~ kg
A
D
H
L
W
F
SB 2506
6
2550
1°15’
18
12
15
15
170
100
350
1900
3300
2120
3100
6200
SB 3006
6
3100
1°15’
15
14
17
15
170
105
350
1950
3850
2120
3100
6900
SB 3010
10
3100
1°30’
10
14
48
22
200
105
350
2000
4150
2210
3550
9920
SB 3013
13
3100
1°45’
11
14
48
30
330
130
500
2100
4150
2210
3850
12500
SB 3016
16
3100
2°
10
14
61
37
410
140
350
2250
4550
2240
3825
14800
SB 3020
20
3100
2°
5
14
77
45
470
150
350
2400
3900
2260
3400
21480
SB 4006
6
4100
1°15’
12
18
22
15
280
120
350
2050
5000
2100
3650
10250
SB 4013
13
4100
1°45’
8
18
62
30
330
160
350
2350
5350
2230
3850
15800
DURMAZLAR
SB
Page 1 / 28
A – 2.1 INTRODUCTION OF THE MACHINE – The machine’s steel welded construction is made from Eregli Demir Çelik St 44-A1 quality material and it’s frame is produced as monoblock. All the tension point are desinged with large radius to prevent welding cracks. – The blades are produced from BOHLER high quality steel and grounded in appropriate valves for every type steel cutting. – The machine has 3 different working advantages, cutting process, retum of table and sheet holders with the pressure cylinders of hydraulic system. Also emergency buttons are supplied as a support security system. – The hydraulic system products are imported from Germany brand name Rexroth. – The hydraulic cylinders are made from SAE 1040 material and inside has been plated and is produced by the European St 52 plane pipes. – The hydraulic pistons are chromium plated with 100 micron and sensitively grinded again until it’s ready. – The hydraulic leakage parts are imported from Germany brands Merkel or Busak Shamban. – DURMAZLAR , hydraulic pipes are made big to decrease the heat. Also hydraulic pipe and fittings needed in minimum quantity. Hydraulic system is strong and appropriate for maximum usage. – When DURMAZLAR develops a hydraulic systems ; reachable valves , high quality material , security and performance will be in high level. – 25 micron sensitiv return filter is used for double filter hydraulic system of suction and return. – The hydraulic pipes are made from St 35.4 quality steel pipes according to DIN 2391 / CY. – The hydraulic connection parts are suitable for DIN 2353. – Hold down pressure is adjustable according to sheet thickness and tensile strength from a valve on regulation block. – Machine cutting gap adjustment is made automatically or manual from one point in total cutting length equally and simultaneously. – Motorized back gauge sheet arrangement up to 1000 mm can be adjusted and the measurement value can be read at 0.1 mm from the digital readout. Also the gauge can be folded 180° infinity. – Back gauge is produced according to enviroment conditions. Back gauge seats with double carriers are produced for heavy conditions. Back gauge seats are equiped double with Thompson seats. It has double ballscrew systems. – Electrical circuit parts are from Siemens, Telemecanique or Merlin Gerin marked products. The command circuit is supplied at 24 volt DC.
DURMAZLAR
SB
Page 2 / 28
– The machine functions has 2 main motors: Hydraulic system motor Back gauge motor – Back gauge motor has speed control. – The machine can be worked in 3 different operation ways. The cuts of “L” type or large radius sheet cuts can done in these positions besides from straight strips cuts. Also in serie cuttings the blade length is automatically adjusted. – There is a shade wire in the cutting where there is no dependant measurement on the machine. – Sheet holders and 90° set-square support have a “T” slot and a front support measurement is applied. – To slide the sheet plate easier there are special transfer balls on the platform of the front table. – The machine’s surface is painted min.60 micron thickness with main paint, which saves against weather and working conditions. – Besides from the operation use of the machine there is a 1 year guaranty against production defects.
A – 3.0 STANDARD AND REQUESTED EQUIPMENT A – 3.1 STANDARD EQUIPMENT - Digital readout command panel - 2 pieces of sheet holders - 1 piece of ruler set - square - 3 pieces of front support apparatus pins - 1 piece of shade wire - Illumination light - 1 piece of command pedal - Special sheet transfer balls on the front table - Ballscrew movement transmission system - Owners manual
A – 3.2 REQUESTED EQUIPMENT - NC Control unit (ELGO , EMKO , NUOVA ) - It is possible to have 200 separate programs for the sheet support distance and cutting amount - If requested the gauge will automatically go back during the cutting process - It can be worked on manual or automatic program command - Special security system and control is contained according to the CE certificate - Special angle set – square for degree cutting - Support arms and 90° set – square with support device up to 3000 mm. - Pneumatic control sheet support system which is assembled on the back gauge.
DURMAZLAR
SB
Page 3 / 28
B – MACHINE AND PERSON SECURITY B – 1.1 INFORMATION FOR HYDRAULIC OIL The required hydraulic oil must be filled in the machine as stated on the number 1 points and this must be done before installing the machine. ( Look at A – 1.1 for the required oil proportion )
HYDRAULIC OIL
PLACES WHERE TEMPERATURE IS BELOW 20°C
PLACES WHERE TEMPERATURE IS ABOVE 20°C
STANDARD NORM ARAL B.P. CALTEX-TEXACO ESSO PURFINA FRANCE HUILE RENAULT-ELF SHELL VALVOLINE VEEDOL YACCO GULF CASTROL
ISO VG 32 VITAN GF 32 HLP 32 RANDO OIL 32 NUTO H 32 HYDRAN 32 OLNA 32 TELLUS 32 ULTRAMAX 32 ANDRAIN 32 TRANSHYD 32 HARMONY 32 AW AWS 32
ISO VG 46 VITAN GF 46 HLP 46 RANDO OIL 46 NUTO H 46 HYDRAN 46 OLNA 46 TELLUS 46 ULTRAMAX 46 ANDRAIN 46 TRANSHYD 46 HARMONY 46 AW AWS 46
GREASE SHEEL B.P.
ALVANIA R 2 ENERGREASE HY 2
B – 1.2 FIRE DATA Flash point ( °C ) and method : 193 closed cup. Auto ignition temperature ( °C ) > 200 Flammability limits : 1.5 – 6 Products of combustion : Mainly oxides of carbon , water vapour with unidentified organic compounds. Special fire / explosion hazards : Large surface areas exposed to air / oxygen ( e.g. , oil-soaked rags , paper or absorbed soillages ) may be easily ignited and these should be cleared up at once. Special fire-fighting procedures : Firefighters should enter area wearing self-contained breathing apparatus. Do not spray water directly into stroge containers due to boil over danger. Extinguishers : Foam , dry chemical powder , carbon dioxide , halon. DURMAZLAR
SB
Page 4 / 28
B – 1.3 STORAGE and REACTIVITY DATA Suitable materials / coatings
: Most common metals.
Unsuitable materials / coatings
: May soften some rubbers.
Stability
: Stable.
Reaction with water
: None.
Dangerous reactions
: None known.
Hazardous polymerisation
: Will not occur.
Materials to avoid
: Strong oxidising agents.
Conditions to avoid
: Extreme temperatures.
Decomposition temperature ( °C )
: > 100
Dangerous decomposition products
: Significant concentrations of hazardous decomposition products are not expected.
Storage temperature ( °C )
: 0 - 40
Storage precautions
: No special reguirements. Avoid elevated temperatures.
B – 1.4 RECOMMENDED FIRST AID IN CASE OF CONTACT WITH HYDRAULIC OIL Eye contact : Flush with plenty of water for at least 15 minutes. If irritation persists , obtain medical attention. Skin contact : Wash with soap , or approved skin cleanser , and water. Remove heavily contaminated clothing. Where skin rashes or other abnormalities occur as a result of excessive contact , medical advice should be obtained. Inhalation : In the event of discomforting effects produced by overexposure , remove to fresh air. If effects persist , obtain medical attention. Ingestion : Milk or water to drink may be beneficial, DO NOT INDUCE VOMITINH. Main hazard is aspiration into the lungs during of following ingestion , childen being more susceptible than adults. If this occurs ( e.g. , during vomiting ) , send to hospital immediately. Notes for doctors : Treat symptomatically. Aspiration may cause sever pneumonitis , requiring antibiotics and corticosteroid therapy.
B – 2.1 PROTECTION OF HAND AND BODY - Always keep your hands away from the cutting axis during cutting. Cutting gap adjustment and protection covers should not be adjusted during the cutting process.The front panel covers and protection covers security switches on the main electrical panel shouldn’t be out of circuit at any time. If machine has a sheet support system the material should be placed carefully. - Don’t get close to the machine during the machines operation. Stay at the given measurement for the security distance. - Never go inside the machine during the cutting process. DURMAZLAR
SB
Page 5 / 28
B – 3.1 PROTECTION SHEETS MONTAGE MEASURE
A
B
6 mm SB
12
