Manual de Sierra Cinta Saw Blade Manual...
BANDSAW MACHINE USER GUIDE
DCB
WARNING !
The images in this catalogue may differ according to the machine you buy.
ORIGINAL GUIDE
HYDRAULIC DOUBLE COLUMN AUTOMATIC BANDSAW MACHINE COMPANY NAME : DCB-S MACHINE TYPE : 560 SERIAL NUMBER : 804213143 ORDER NUMBER : DATE
222101
: 19.12.2013
2
ORIGINAL GUIDE CONTENTS -
Contents
PAGE 3
-
Foreword
6
-
About Durmazlar
7
-
EC Declaration of conformity
8
PART 1 – GENERAL SAFETY WARNINGS 1.1 Safety Instructions
9
1.2 Unavoidable Risks
13
PART 2 – GENERAL MACHINE PRESENTATION 2.1 About the Machine
16
2.2 Machine presentation
17
2.3 Presentation and warning tags fixed onto the machine
18
2.3 Prohibited applications
26
2.4 Safety members and switches in the machine
29
2.5 Safety regions of the machine
31
2.6 Technical machine data
32
§
DCB-A 360 Technical specifications
32
§
DCB-S 360 Technical specifications
33
§
DCB-A 460 Technical specifications
34
§
DCB-S 460 Technical specifications
35
§
DCB-A 560 Technical specifications
36
§
DCB-S 560 Technical specifications
37
§
DCB-A 800 Technical specifications
38
§
DCB-S 800 Technical specifications
39
§
DCB-A 1100 Technical specifications
40
§
DCB-S 1100 Technical specifications
41
§
DCB-A 1600 Technical specifications
42
§
DCB-S 1600 Technical specifications
43
§
DCB-M 460 Technical specifications
44
§
DCB-M 560 Technical specifications
45
§
DCB-M 800 Technical specifications
46
§
DCB-DM 560 Technical specifications
47
§
DCB-FA 330 Technical specifications
2.7 Main parts of the machine 2.8 Standard and optional accessories in the machine 2.8.1 Standard accessories
48 49 53 54
2.8.2 Optional accessories
55
2.8.3 Particular solutions
56
2.9 Noise 2.9.1 Noise level measurements 2.10 Standards used in the saw design
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56 56 57
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ORIGINAL GUIDE
PART 3 – INSTRUCTIONS FOR MACHINE TRANSPORTATION 3.1 Transportation of the machine
59
3.2 Removal of the package
60
PART 4 – STORING CONDITIONS
61
PART 5 – MACHINE INSTALLATION INSTRUCTIONS 5.1 Operating area of the machine
62
5.2 Machine installation
62
5.3 Machine placement
63
5.4 Electrical connections
63
5.4.1 Motor direction
64
5.4.2 Motor current values
64
5.5 First checks
65
5.5.1 Cooling liquid
65
5.5.2 Hydraulic Unit
65
5.5.3 Hydraulic Unit Cleaning
66
5.5.4 Hydraulic Unit pressure adjustment
67
PART 6 – INSTRUCTIONS FOR COMMISSIONING THE MACHINE 6.1 Commissioning
68
6.2 Powering
69
6.3 Confirmation of the Machine
70
PART 7 – USAGE INSTRUCTIONS 7.1 User region
70
7.1.1 Prior to Cutting
71
7.1.2 Cutting
71
7.1.3 Language Selection
72
7.1.4 Counter usage
72
7.1.5 Digital potentiometer 7.2 Operating the machine
72 73
7.2.1 Manual cutting
73
7.2.2 Automatic cutting
74
7.2.3 Siemens Simatic Panel
75
7.2.2 Turning off the Machine
84
7.2.3 Restarting the machine which is stopped emergently
85
7.3 Presentation of the buttons
85
7.4 Clamp usage
86
PART 8 – MAINTENANCE, REPAIRING AND CLEANING INSTRUCTIONS 8.1 Saw blade adjustment
87
8.2 Maintenance information
87
8.2.1 Daily maintenance
87
8.3.2 Weekly maintenance
88
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ORIGINAL GUIDE 8.4.3 Monthly maintenance
88
8.3 Changing of blades
89
8.4 Information about the lubricant used in the machine
89
PART 9 – TROUBLESHOOTING DATA 9.1 Probable failures
90
9.2 Inverter failure codes and the descriptions thereof
90
PART 10 – HEALTH AND SAFETY OF THE OPERATOR 10.1 Rescue of the Squeezed Personnel 10.2 Properties of the hydraulic lubricant used
95 96
10.2.1 Transportation
97
10.2.2 Storing
98
10.2.3 Definitions of the dangers
98
10.2.4 Recommended first aid
98
10.2.5 Control of usage and individual protection
99
10.2.6 Toxic data
99
10.2.7 Disposal data
99
PART 11 – DECOMMISSIONING
101
PART 12 – FEEDBACK FORM
102
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ORIGINAL GUIDE
FOREWORD
This handbook is prepared so as to comprise the required information with the required techniques taking into account the object of more actively and effectively usage of the machines serving you. Our first principle is to provide you the maximum performance with our machines which are produced using the most qualitative materials, the state-of-the-art technology and engineering services. Our products which have the minimal operating costs will serve you for several years if you care for their periodical maintenance and if you carry out the periodical maintenance regularly. Press brakes which are among our products are used in bending of sheets with pluralities of thicknesses and qualities, and the shears and saws are used in cutting of different materials (Sheet plate, Aluminum, Cu, plastic, paper, etc.). This handbook should be read at least once by the operating responsible and also by the stuff operating the machines. The handbook should be in the vicinity of the machine, this is important for the troubleshooting of the failures which may occur. Our factory has the rights to realize the required novelties according to the improving technology without appealing to any authority. Our situation in the domestic market which we serve since 1956 has become higher since we are in the international market for 30 years. Thus, the experience and the technological improvements obtained from this market are presented to you in the best manner. Congratulations with your machine and we wish you success in your works.
DURMAZLAR MAKINA SAN. VE TIC. A.S. Organize Sanayi Bölgesi 75. Yil Caddesi BURSA Tel : + 90 224 219 18 00 pbx. Fax : + 90 224 242 75 80 – 242 93 73 Internet : www.durmazlar.com.tr e-mail :
[email protected] [email protected]
666101
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ORIGINAL GUIDE
ABOUT DURMAZLAR A.S Durmazlar Machine is one of the leading machine manufacturers in Turkey and it is the leader of the market in terms of the production numbers. Durmazlar is one of the leading industrial institutions of Turkey, which improves the production and services thereof continuously. Durmazlar realizes production in international standards, it represents Turkey in the world and it contributes to the national income. Today, Durmazlar Machine is a company which is older than 50 years, it has a closed production area equal to 150000 m2, it has 1000 personnel and it realizes exportation to 82 countries and Durmazlar Machine always tries to do the best. Durmazlar Machine has the principle of production in world standards, it realizes investments in novel technologies and it presents the products thereof with suitable prices. Durmazlar is the first country in Turkey which produces sheet processing machines; and the following products are among the products of Durmazlar: CNC Hydraulic press, full automatic press, CNC Hydraulic shear, Punch press, Plasma Cutting and Laser cutting machines, Hydraulic Cylinder, Asymmetric Cylinder, Profile Bending, Manual Cylinder, Circle Cutting, Cord and Saw Machines. These have a wide usage area in sectors like automotive, construction, textile, electronics, air transportation, marine transportation and defense industry. The production process, which is realized with very sensitive process machines, provides our products to function with high performance after long years; and during this process, processes like automatic welding and tension elimination are realized under the light of this object. Durmazlar Machine has sensitive processing CNC centers up to 20 meters in one piece; and it increases this production standard by means of the laser technology. Durmazlar Machine supports the customers thereof in both standard machine production and in particular machine production. For preserving and maintaining DURMA quality, the products are tested with high technology tests in all of the production steps. Durmazlar exists as long as it assures to the customers and since according to the vision of Durmazlar the most valuable investment is person, Durmazlar improves itself continuously and it always tries to provide better customer service. DURMAZLAR MAKINA SAN. VE TIC. A.S. Organize Sanayi Bölgesi 75. Yil Caddesi BURSA Tel : + 90 224 219 18 00 pbx. Fax : + 90 224 242 75 80 – 242 93 73 Internet : www.durmazlar.com.tr e-mail :
[email protected] [email protected]
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ORIGINAL GUIDE
EC DECLARATION OF CONFORMITY AT UYGUNLUK BEYANI MANUFACTURER IMALATÇI
DURMAZLAR MAKINE SAN. VE TIC. AS.
ADDRESS Organize Sanayi Bölgesi 75. Yil Cd. 16159 Bursa - Türkiye ADRES Name and address of the person authorised to Ramadan Kelebek compile the technical file Organize Sanayi Bölgesi 75. Yil Cd. 16159 Bursa - Türkiye Teknik Dosyayi derleyen yetkili kisi ve adresi The undersigned Company certifies under its sole responsibility that the item of equipment specified below satisfies the requirements of the Machinery Directive 2006/42/EC which is apply to it. The item of equipment identified below has been subject to internal manufacturing checks with monitoring of the final assessment by DURMAZLAR MAK.SAN.TIC.AS. Asagida tanimlanmis olan ekipmanlar için Machine Emniyeti yönetmeligi 2006 / 42 / AT’nin uygulanabilen gerekliliklerinin yerine getirildigini ve sorumlulugun alinmis olundugunu beyan ederiz. Asagida tanimlanan ekipmanlar iç üretim kontrollerine bagli olarak DURMAZLAR MAK.SAN.TIC.AS. tarafindan kontrol edilmistir. PRODUCT
Double Column Bandsaw
ÜRÜN
Çift Sütunlu Serit Testere
MODEL / TYPE
DCB -S 560
SERIAL NO
804213143
DIRECTIVES / YÖNETMELIKLER MACHINERY DIRECTIVE 2006/42/EC MAKINE EMNIYETI YÖNETMELIGI 2006/42/AT LOW VOLTAGE DIRECTIVE 2006/95/EC BELIRLI GERILIM SINIRLARI DÂHILINDE ÇALISMAK ÜZERE TASARLANMIS ELEKTRIKLI TECHIZAT YÖNETMELIGI 2006/95/AT ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC ELEKTROMANYETIK UYUMLULUK YÖNETMELIGI 2004/108/AT Regulations Applied acc. to HARMONIZE STANDARDS UYGULANAN UYUMLASTIRILMIS STANDARTLAR
EN12622:2001 ;EN ISO 4414:2010 ;EN ISO 4413:2010 ;EN 999:1998 ; EN ISO 13849-1:2009 ;EN 13857:2008 ;EN 602041:2011 ;EN ISO 12100:2010 Place and date of issue
: Bursa, 19.12.2013
Yer ve Tarih Name and position of authorized person
: Ramadan KELEBEK Researching-Development Dep. Manager / Ar-Ge Müdürü
Yetkili kisinin adi ve görevi Singanature of authorized person
:
Yetkili kisinin imzasi
888101
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ORIGINAL GUIDE PART 1 – GENERAL SAFETY WARNINGS 1.1 Safety Instructions Attention
• • • •
Before operating the machine, read the users manual. If you have a question about the machine, please contact with the manufacturer company.
In cases where operator intervention is required on the machine, READ the user manual prior to intervention. Before using the machine, check the required fixtures (material table, chip conveyor, etc.) and operate the machine so as to be compliant with the values given in the presentation tag. While the machine is operating, be sure to be in the control panel region mentioned in Figure 1.2. Otherwise, accidents may take place. NEVER! approach the saw blade or the other moving parts without wearing gloves, protective clothes and eye-glasses. (Figure-1.1) Do not approach the Open Region of the Blade without taking precautions
Figure 1.1 - Wrong
Figure 1.2.-Correct
Do not forget to fix the Blade Protector while changing the band
Figure 1.3. • When the user desires to work on the open region of the blade, or when the blade is required to be changed, fix the blade protector in order for the teeth not to give damage to you or in order for the teeth not to be damaged. (Figure-1.3). • Wear gloves when the blade is to be changed.
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ORIGINAL GUIDE • There is emergency stop button on the control panel of the machine (Figure-1.4). The emergency stop stops all of the dangerous movements. • Do not approach the machine while the machine is being operated. If there is a very important case, turn off the machine and activate the emergency stop. • Prior to maintenance, ALWAYS be sure that the machine is in STOPPED position.
Emergency Stop Button
Figure -1.4 • The service process should be carried out by the authorized personnel only. • Do not wear wide and long clothes and do not wear tie in order to prevent being caught by the movable parts. • For safety, the dangerous regions are covered by guards. During the operation of the machine or after maintenance, these covers should always be in closed position. • Be far away from the cutting region against the throwing danger of the work piece. • While the machine is being operated, do not try to open the electrical panel. Prior to opening the electrical panel, de-energize the machine and pull the plug. • The machine should not be operated over the capacity thereof. • The machine is designed so as to be operated with one (1) operator. • Prior to using the machine, check if the safety mechanisms function well. • Keep third party away from the machine. • The operator should wear shoes with steel end parts in the front in order to protect against being crushed as a result of the falling of the work piece. • The operator should work using gloves. • The operator should wear protective eye-glasses while working.
101010101
10
ORIGINAL GUIDE • Keep the operating area tidy. Untidiness in the operating region leads to fault and danger. It limits your actions. • Prior to powering the machine, the grounding should be checked. Realize the grounding of the machine using copper grounding cable in the region in Figure 1.5.
Figure -1.5 • Be compliant with the Maintenance Instructions. • Be careful that at least three sides of the region, where the machine is to be placed, are open. If possible, prefer closed regions. • Do not remove and de-activate or do not change the places of the Safety Members and Protective members. • Do not operate the machine without putting cooling liquid and hydraulic lubricant. For lubricant selection, please look at the Lubrication Schemas table. • In cases where the machine will not be operated for one week or for longer durations, loosen the blade for increasing the blade’s life. • Change the reducer lubricant at the end of the first 2000 hours. • There has to be material between the clamps in order for the cutting process to be realized. • There are two stops in the cutting motor for safety purposes. Emergency stop mushroom button stops cutting in saw in time duration shorter than 1 second, the stop button stops cutting in 2-3 seconds. However, usage of the emergency stop button continuously shortens the motor and inverter life. • In the cutting of pieces which are longer than 300 mm, since the falling of the piece from the machine leads to accidents, material table is recommended to be used.
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11
ORIGINAL GUIDE • When the machine is not in use, do not leave material under the blade. The guided body may move downwardly as a result of the gravitational force, and may lead to the breakage of the blade. When the blade will not be used for a long time, loosen the blade. The position of the material when the machine will not be operated.
Figure 1.6 - Wrong-
Figure 1.7 - Correct
• Bring the Rectification Arm to the closest position to the material/materials to be cut, and realize the cutting process. Otherwise, the material vibrates, the blade teeth may be broken and the chips or broken teeth may be thrown and this may lead to injuries.
Position of the Rectification Arm
Figure 1.8 -Wrong
Figure 1.9 -Correct
• Carry the machine by holding the machine from the tagged regions. If you carry the machine from different points, you may be hurt and your machine may be damaged. 121212101
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ORIGINAL GUIDE
Figure -1.10 1. 2 UNAVOIDABLE RISKS • Since the cutting bandsaw can not be closed by any casing, while cutting and/or while operating in the idle mode, there will be accidents in case the workers approach their hands or fingers.
Figure 1.11 • While the guided body moves upwardly-downwardly, if the worker approaches the body, there may become accidents. Keep far away from the movable members.
131313101
13
ORIGINAL GUIDE • Look at the weight of the removable pieces from the piece list, do not lift and do not try to lift pieces heavier than 15 kg without using auxiliary equipment (hoist, crane, etc.).
Figure 1.12
ATTENTION!
Lifting heavy loads gives permanent damages to your body.
• The intermediate distance between the rotating helix and the conveyor groove sheet is 10 mm (Figure 1-13). In order to prevent accidents while the chip conveyor is functioning, be careful with the rotating helix region.
Figure -1.13 141414101
14
ORIGINAL GUIDE • The machine with the rotating table can rotate 60° in clockwise direction. As can be seen in Figure 1-14 and Figure 1-15, while rotating the machine with the rotating table, be sure that the machine is not in the safety distances below. Otherwise, there may be accidents.
Figure -1.14
151515101
Figure -1.15
15
ORIGINAL GUIDE PART 2 – GENERAL MACHINE PRESENTATION 2.1 About the machine
Today, among the benches whose usage is simple, the best and most rapid metal cutting is realized by bandsaw machines. In the flat or angled cutting of iron, copper alloys, aluminum alloys, production steels, carbon steels, hot-cold work tool steels, case hardened steels, mould steels, nickel chrome alloyed steels, bearing steels, stainless steels, titanium alloys, castings, construction steels and non-iron metals, metal bandsaw machines are used. The cutting process can be realized one by one, the multiple cutting of materials in binding form can be realized in a comfortable manner. In iron steel factories, in plane industry, ship industry, automotive industry, production industry, in construction sector, in aluminum industry; it is mostly used since it has a low cost and since it is rapid. Thanks to the reinforced body structure, the bending and vibrations formed during cutting are minimized. These rigid bodies are connected to the reinforced chassis by means of columns which are covered by chrome, and a strong frame is formed. All of the tensions of the body, chassis and other accessories are eliminated by means of the tension eliminating device after the welding and casting process. In 5 axis CNC processing centers, all of the processes are realized in one binding. Thanks to this, the parallelism of all of the axes and surfaces is provided. These processes provide sensitivity and strength to the DURMA HB and DCB series bandsaw machines for long years.
The usage and publication rights of the information given in this document belong only to DURMAZLAR MAK.SAN.TIC A.S. Without the permission of the company, it can not be copied, published and used in any manner. Said company can change the specifications and pieces existing in said guide without informing beforehand. The figures and schemas existing in the guide can be different from the product.
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ORIGINAL GUIDE 2.2 Machine presentation
DCB series Bandsaw Machines are benches which are used for cutting partially cold or cold (iron or non-iron) metals by means of the saw blade.
Figure 2.1
Our machines, which are designed and manufactured as pivot type and column type in the TS EN 13898, meet the customer needs in the highest level.
ATTENTION!
Do not use the machine for wrong purposes. The manufacturer is not responsible if the machine is used for wrong purposes.
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ORIGINAL GUIDE PRESENTATION AND WARNING TAGS FIXED ONTO THE MACHINE
Tag : 1
Tag : 2
Tag : 3
Tag : 8 Tag – 8 : Electrical warning tag
Tag : 4
Tag : 5
Tag : 6
Tag : 7
Tag – 1: The person using the machine should read the user manual. Tag – 2: Protective Eye-Glass should be used. Tag – 3: Turn off when not in use. Tag – 4: Cutting Tool Warning. Tag – 5: Throwing Danger Warning. Tag – 6: The user should wear shoes with steel end parts. Tag – 7: The user should wear gloves. CUTTING PRESSURE
0
GETK.8032.007
Tag : 9
Tag : 10
Tag : 11
Tag : 13
Tag : 12
Attention
181818101
Tag – 9: This is the tag which illustrates the safety instruction which the user should obey. Tag – 10: Tightening Pressure Tag Tag – 11: Saw Blade Lowering Speed Adjustment Tag Tag – 12: Grounding tag Tag – 13: Motor rotation direction tag
Do not operate the machine without filling the Hydraulic Lubricant and cooling liquid!
18
ORIGINAL GUIDE
Tag : 14
Tag : 15
Tag – 14: The tag illustrating the rotation direction of the saw blade. Tag – 15: The tag illustrating the rotation direction of the saw blade.
Tag : 16 Tag – 16 : Lubrication Tag
Tag : 17 Tag – 17 : Illumination Tag
Tag : 18
Tag – 18 : Clamp Tightening Tag Tag : 19 Tag – 19 : Blade Tensioning Tag
Attention If the machine will not be used for one week or for a longer time, in order to lengthen the blade life time, loosen the blade.
191919101
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ORIGINAL GUIDE
Tag : 20
Tag : 21
Tag – 20 Type Tag (Machine type, Manufacturing Year, Serial Number, Capacity, Outer Dimensions and Weight) Tag – 21 Electrical Values Tag (Motor Power, Phase, Frequency, Operating Voltage, Control Voltage, Current, Intermediate Fuse Current, Electrical Circuit Number).
Tag : 22
Tag : 23
Tag – 22 Danger of Hydraulic High Pressure Tag – 23 Danger of Blade Pressure
Attention
202020101
Change the reducer lubricant at the end of the first 2000 hours.
20
ORIGINAL GUIDE
Tag – 24 Cutting Information Tag According to the Chips Obtained from the Cut Product
Tag – 25 Blade Selection Tag According to the Material to be Cut
WARNING In order for the cutting process to be realized, there has to be material between the clamps. 212121101
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ORIGINAL GUIDE
Tag – 26 Cutting Values Tag According to the Material to be Cut
Tag – 27 The tag illustrating the presence of the chip conveyor
Tag – 29 Warning Tag
Tag – 28 Upper Press Downward-Upward Tag
Tag – 30 Do not open machine guards unless machine is turned off.
WARNING As a safety precaution, there are two stops in the cutting motor. Emergency stop mushroom button stops the cutting in the saw in a time shorter than 1 second and the stop button stops cutting in 2-3 seconds. However, if the emergency stop button is used frequently, the motor and inverter life is shortened.
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ORIGINAL GUIDE
Tag – 31 Rulers (It illustrates the length and angle value of the material to be cut)
Blue ground
Tag Basilacak Tag––32 32 Yag It illustrates theGrasörlükleri lubricators where lubricant gösterir is to be applied
232323101
Yellow ground
Red ground
Tag – 33 It illustrates the lubricators where lubricant is to be applied
23
ORIGINAL GUIDE
Tag – 34 Warning and Precaution Tag (It illustrates the risks which can be encountered and the precautions to be taken)
Tag – 35 Manufacturer’s Symbol
242424101
24
Tag –27 Material Tag
ORIGINAL GUIDE
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25
ORIGINAL GUIDE 2. 3 Prohibited Applications
Since the cutting bandsaw can not be closed by any casing, while cutting and/or while operating in the idle mode, there will be accidents in case the workers approach their hands or fingers.
Figure 2.2 While the guided body moves downwardly-upwardly, if the worker approaches the guided body, accidents may occur. Keep far away from the movable members.
Figure 2.3
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ORIGINAL GUIDE Look at the piece list for the weight of the removable pieces. Do not lift and do not try to lift pieces heavier than 15 kg without using auxiliary equipment (hoist, crane, etc.).
ATTENTION!
Lifting heavy loads gives permanent damages to your body.
The intermediate distance between the rotating helix and the conveyor groove sheet is 10 mm. In order to prevent accidents while the chip conveyor is functioning, be careful with the rotating helix region.
Figure -2.4
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ORIGINAL GUIDE The machine with the rotating table can rotate 60° in clockwise direction. While rotating the machine with the rotating table, be sure that the machine is not inside the safety distances below. If a worker exists inside the machine rotation region illustrated in Figure 2-6, accidents can take place.
Figure -2.5
Figure -2.6
ATTENTION! The body is rotated by hand. After the body is brought to the desired angle, do not lock the body!
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ORIGINAL GUIDE
Upper Level Switch
2.4 Safety members and switches in the machine
Right Cover Switch
Left Cover Switch
Lower Level Switch
Emergency Stop Button
Material Finish Switch
Figure -2.7
cil Stop LOWER LEVEL SWITCH (LIMIT SWITCH) It lifts the saw head upwardly when the saw head reaches the lowest level. COVER SWITCHES (LIMIT SWITCH) It prevents the operation of the machine while the cover is open. MATERIAL FINISH SWITCH (MATERIAL SWITCH) The switch which contacts with the automatically driven material does not contact with the material and the material is finished and it stops the driving process. EMERGENCY STOP BUTTON (EMERGENCY STOP) When pressed in an emergent case, it electrically stops the machine. There are two stops in the cutting motor as a safety precaution. Emergency stop mushroom button stops the cutting process in the saw in a time shorter than 1 second and it stops the button in a time longer than 2 seconds. However, if the emergency stop button is pressed frequently, the motor and inverter life is shortened. 292929101
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ORIGINAL GUIDE
BLADE TENSIONING SWITCH (VICE SWITCH)
TENSION SWITCH: When the blade is broken or when the blade loses the tension, it stops the machine. Tension switch
Figure -2.8 COVER SWITCHES
Do not leave Cover Switches open.
Figure -2.9
Keep Cover Switches in Closed Position.
Figure -2.10
ATTENTION! While the protective covers are open, thanks to the switches with XCSA701 CE, the machine is prevented from being operated. When the cover is open, the machine does not function! Cover switches can be positioned on the cover or next to the cover. This does not change the abovementioned warnings.
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ORIGINAL GUIDE 2.5 Safety regions of the machine
THE MA TER IAL TO BE CUT
THE CUT MATERIAL + 500
Figure -2.11 For the correct placement of the machine, the placement dimensions and the space distances to be left in the periphery thereof are mentioned below:
Placement Dimensions A: 2060 mm. B: 1000 mm. Space Distances A1: 1200mm. A2: 800 mm. B1: 3000 mm. B2: 3000 mm.
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ORIGINAL GUIDE Figure -2.112
2.6 Technical machine data
DCB-A 360 TECHNICAL SPECIFICATIONS
A
H
DURMA
300
W
L
DCB-A 360 Cutting Capacity
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Dimen Motors sion
Main Motor Hydraulic Pump Motor Material Driving Motor Cooling Motor Length (L) Width (W) Height (H) Cutting Speed Blade Dimensions Working Height (A) Oil Tank Capasity Weight
323232101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
Double Column Bandsaw Automatic 360 360 360x380 2,2 0,55 0,25 0.09 2480 1100 1615 20 ~ 80 Inverter 34x1,1x4570 540 8 1650
32
ORIGINAL GUIDE
DCB-S 360 TECHNICAL SPECIFICATIONS
A
H
DURMA
320
W
L
HORIZONTAL BANDSAW HALF AUTOMATIC
DCB-S 360
Cutting Capacity
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Machine Dimensions
Motors
Main Motor Hydraulic Pump Motor Blade Rotation Motor Cooling Motor Length Width Height Cutting Speed Blade Dimensions Working height Oil Tank Capasity Weight 333333101
(L) (W) (H)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
Standard
Rotating Table
360 360 500x360 280 280 280x360 160 160 160x360 -
360 360 360x380 280 280 280x360 160 160 160x360 2,2 0,55 0.09
2480 2480 1100 1250 1615 1715 20 ~ 80 Non-gradual Electronics 34x1,1x4570 540 640 8 1500 1750 33
ORIGINAL GUIDE
DCB-A 460 TECHNICAL SPECIFICATIONS
A
H
DURMA
480
W
L
Double Column Bandsaw Automatic
DCB-A 460
Cutting Capacity
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Dimen sion
Motors
Main motor Hydraulic pump motor Material Driving Motor Cooling Motor Length (L) Width (W) Height (H) Cutting Speed Blade dimensions Working Height (A) Oil Tank Capasity Weight 343434101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
460 460 460x470 3 1,1 0,75 0.09 3000 1150 1820 20 ~ 90 Inverter 41x1,3x5800 580 18 2300 34
ORIGINAL GUIDE
DCB-S 460 TECHNICAL SPECIFICATIONS
A
H
DURMA
320
W
L
HORIZONTAL BANDSAW HALF AUTOMATIC
DCB-S 460
Cutting Capacities
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Machine Dimen sions
Motors
Main motor Hydraulic pump motor Blade Rotation Motor Cooling Motor Length Width Height Cutting Speed Blade Dimension Working height Oil Tank Capasity Weight 353535101
(L) (W) (H)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
Standard
Rotating Table
460 460 460x620 460 460 460x500 310 310 460x310 -
460 460 460x620 460 460 460x440 290 290 460x290 120 120 460x120 3 1,1 0.09
3000 3000 1000 1250 1900 2000 20 ~ 90 Inverter 41x1,3x5800 580 680 18 2090 2470 35
ORIGINAL GUIDE
DCB-A 560 TECHNICAL SPECIFICATIONS
A
H
DURMA
480
W
L
Double Column Bandsaw Automatic
DCB-A 560
Cutting Capacity
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Dimen sion
Motors
Main Motor Hydraulic pump motor Material Driving Motor Cooling Motor Length Width Height Cutting Speed Blade dimensions Working Height Oil Tank Capasity Weight 363636101
(L) (W) (H)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
560 560 560x610 4 1,1 1,1 0.09 3300 1150 2040 20 ~ 90 Inverter 41x1,3x7000 580 18 2600 36
ORIGINAL GUIDE
DCB-S 560 TECHNICAL SPECIFICATIONS
A
H
DURMA
320
W
L
DCB-S 560
Cutting Capacities
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Machine dimen sions
Motors
Main motor Hydraulic pump motor Blade Rotation Motor Cooling Motor Length Width Height Cutting Speed Blade dimensions Working Height Oil Tank Capasity Weight
373737101
(L) (W) (H)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
HORIZONTAL BANDSAW HALF AUTOMATIC Standard Rotating table 560 560 560 560 560x750 560x750 560 560 560 560 560x600 560x560 430 380 430 380 560x430 560x380 160 160 560x160 4 1,1 0.09 3400 3400 1150 1300 2040 2140 20 ~ 90 Inverter 41x1,3x7000 580 680 18 2450 2850
37
ORIGINAL GUIDE
H
DCB-A 800 TECHNICAL DATA
A
B
C
DURMA
W
L
Hydraulic Double Column Automatic Bandsaw Machine
DCB-A 800 Round Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length Width Height Clamp height
Dimensions
Motor Powers
Cutting Capacities
90º
(L) (W) (H) (B) Hydraulic Upper Press Height (C) Cutting speed Blade dimensions Working height (A) Weight Oil Tank Capasity Blade Twisting Angle
383838101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm mm m/min mm mm Kg Lt. º
800 800 800x920 7,5 1,5 Hydraulic 0,37 3970 2000 2660 470 500 20 ~ 90 Non-gradual Electronics 54x1,6x8600 660 4500 45 60º
38
ORIGINAL GUIDE
DCB-S 800 TECHNICAL SPECIFICATIONS
A
H
DURMA
W
L
HORIZONTAL BANDSAW HALF AUTOMATIC
DCB-S 800 CUTTING CAPACITIES
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Machine Dimen sions
Motors
Main motor Hydraulic pump motor Blade rotation motor Cooling motor Length Width Height Cutting speed Blade dimensions Working height Oil Tank Capasity Weight 393939101
(L) (W) (H)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
800 800 800x90 700 720 800x700 530 530 800x530 7,5 1,5 0,37 3970 1380 2660 20 ~ 90 Inverter 54x1,6x8600 660 45 3400 39
ORIGINAL GUIDE
H
DCB-A 1100 TECHNICAL DATA
A
B
C
DURMA
W
L
DCB-A 1100 Round Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length (L) Width (W) Height (H) Clamp height (B) Hydraulic Upper Press Height (C) Cutting speed Blade dimensions Working height (A) Weight Oil Tank Capasity Blade twisting angle Dimensions
Motor Powers
Cutting Capacities
90º
404040101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm mm m/min mm mm Kg Lt. º
Hydraulic Double Column Automatic Bandsaw Machine 1100 1100 1100x1300 11 3 Hydraulic 0,37 5500 2400 3400 650 680 20 ~ 90 Non-gradual Electronics 67x1,6x12000 680 9400 45 65º
40
ORIGINAL GUIDE
DCB-S 1100 TECHNICAL SPECIFICATIONS
A
H
DURMA
W
L
HORIZONTAL BANDSAW HALF AUTOMATIC
DCB-S 1100 CUTTING CAPACITIES
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Machine Dimen sions
Motors
Main motor Hydraulic pump motor Blade rotation motor Cooling motor Length (L) Width (W) Height (H) Cutting speed Blade dimensions Working height (A) Oil Tank Capasity Weight 414141101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
1100 1100 1100x1300 840 840 1100x840 640 640 1100x640 11 2,2 0,37 5500 1660 3400 20 ~ 90 Inverter 67x1,6x12000 680 45 7500
41
ORIGINAL GUIDE
A
B
DURMA
W
H
DCB-A 1600 TECHNICAL DATA
W
L
Double Column Half Automatic Bandsaw Machine
DCB-A 1600
Dimensions
Motor Powers
Cutting Capacities
Round 90º Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length (L) Width (W) Height (H) Clamp height (B) Cutting speed Blade dimensions Working height (A) Weight Oil Tank Capasity Blade twisting angle 424242101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm m/min mm mm Kg Lt. º
1600 1600 1600x2050 0,55 ~7500 ~3600 ~5200 ~1000 20 ~ 100 Non-gradual Electronics 80x1,6x16000 ~800 ~22000 ? 90º 42
ORIGINAL GUIDE
A
B
DURMA
W
H
DCB-S 1600 TECHNICAL DATA
W
L
DCB-S 1600 Round Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length Width Height
Dimensions
Motor Powers
Cutting Capacities
90º
(L) (W) (H) Minimum Saw Body Height (W) Clamp height (B) Cutting speed Blade dimensions Working height (A) Weight Oil Tank Capasity Blade twisting angle
434343101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm mm m/min mm mm Kg Lt. º
Double Column Half Automatic Bandsaw Machine 1600 1600 1600x1600 1200 1200 1600x1200 900 900 1600x900 18,5 4 0,55 ~6100 ~2200 ~4350 ~3000 1000 20 ~ 100 Non-gradual Electronics 80x1,6x16000 680 ~12500 ? 90º
43
ORIGINAL GUIDE
DCB-M 460 TECHNICAL DATA
DCB-M 460 Round Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length Width Height Clamp height Cutting speed Blade dimensions Working height Weight Oil Tank Capasity Blade twisting angle Dimensio Motor ns Powers
Cutting Capacities
90º
444444101
(L) (W) (H) (B)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm m/min mm mm Kg Lt. º
Hydraulic Double Column OneDirectional Angled Cutting Bandsaw Machine 460 460 460x620 460 460 460x440 290 290 460x290 120 120 460X120 3 1,1 0.09 3000 1250 2000 280 20 ~ 90 Non-gradual Electronics 41x1,3x5800 680 2140 18 60º 44
ORIGINAL GUIDE
DCB-M 560 TECHNICAL SPECIFICATIONS
HORIZONTAL BANDSAW HALF AUTOMATIC Standard Rotating table
DCB-M 560
Cutting Capacities
90º
60º
45º
30º
Round Square Rectangle Round Square Rectangle Round Square Rectangle Round Square Rectangle
Machine Dimen sions
Motors
Main motor Hydraulic pump motor Blade rotation motor Cooling motor Length (L) Width (W) Height (H) Cutting speed Blade dimensions Working height (A) Oil Tank Capasity Weight
454545101
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm m/min mm mm Lt. Kg
580 560 560x1050 580 560 560x880 580 560 560x700 470 470 560x470 7,5 1,5 0,37 4100 2080 2620 20 ~ 100 Inverter 54x1,6x8200 780 18 5300
45
ORIGINAL GUIDE
DCB-M 800 TECHNICAL DATA
DCB-M 800 Round Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length Width Height Clamp height Cutting speed Blade dimensions Working height Weight Oil Tank Capasity Blade twisting angle Dimen sions
Motor Powers
Cutting Capacities
90º
464646101
(L) (W) (H) (B)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm m/min mm mm Kg Lt. º
Hydraulic Double Column OneDirectional Angled Cutting Bandsaw Machine 800 800 800x920 550 550 800x550 400 400 800x400 200 200 800x200 7,5 1,5 0,37 3970 1720 2890 470 20 ~ 90 Non-gradual Electronics 54x1,6x8600 885 5860 45 60º 46
ORIGINAL GUIDE
DURMA
A
B
H
DCB-DM 560 TECHNICAL DATA
W
W
DCB-DM 560 Round Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length Width Height Clamp height Cutting speed Blade dimensions Working height Weight Blade twisting angle Dimen sions
Motor Powers
Cutting Capacities
90º
474747101
(L) (W) (H) (B)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm m/min mm mm Kg º
Hydraulic Double Column OneDirectional Angled Cutting Bandsaw Machine 580 560 560x1050 580 560 560x880 580 560 560x700 470 470 560x470 7,5 3 0,37 4100 2080 2620 450 20 ~ 100 Kademesiz Elektronik 54x1,6x8200 780 5300 60º
47
ORIGINAL GUIDE
DCB-FA 330 TECHNICAL DATA
A
B
H
DURMA
W
L
Hydraulic Dual Column Fully Automatic Band Saw Machine
DCB-FA 330
Dimen sions
Motor Powers
Cutting Capacities
Round 90º Square Rectangle Round 60º Square Rectangle Round 45º Square Rectangle Round 30º Square Rectangle Cutting motor Hydraulic motor Material driving motor Cooling motor Length Width Height Clamp height Cutting speed Blade dimensions Working height Weight Blade twisting angle
484848101
(L) (W) (H) (B)
(A)
mm mm mm mm mm mm mm mm mm mm mm mm kW kW kW kW mm mm mm mm m/min mm mm Kg º
330 330 330x370 310 310 330x310 220 220 330x220 120 120 330x120 1,5 0,55 1,1 0.09 1950 2150 1710 200 20 ~ 100 Kademesiz Elektronik 27 x 0,9 x 3900 700 1200 90º
48
ORIGINAL GUIDE 2.7 The main pieces of the machine The frontal view of the machine
Figure -2.13 1
BODY
Figure / Code Number B8042010100
2
LOWER COLUMN BEARING
B8042020001
17
DURMA DURMA
Piece number
PIECE NAME and STANDARD NUMBER
Weight KG 220
COMPANY / CERTIFICATE DURMA
3
CUTTING TABLE
B8042020100
260
4
RIGHT FRONT COVER
B8042032900
--
DURMA
5
DRIVE ROLLER
B8042030802
52
DURMA
6
LEFT RECTIFICATION ARM
B8042031501
34
DURMA
7
LEFT FLAP
B8042030201
140
DURMA
8
IDLE ROLLER
B8042030801
49
DURMA
9
LEFT FRONT COVER
B8042032900
--
DURMA
10
TELESCOPIC BLADE PROTECTION
B8042031100
--
DURMA
11
ELECTRICAL PANEL
336709000514
48
EKINPANO/CE
12
BLADE
2010901410
--
LENOX / CE
13
MOVABLE CLAMP
B8042020700
130
DURMA
14
LENGTH ADJUSTMENT MECHANISM
B8032180001
--
DURMA
15
LOOPHOLE
B8032061004
20
DURMA
16
CHIP BOX
B8046180700
--
DURMA
17
FIXED CLAMP
B8042020600
180
DURMA
18
BRUSH GUARD
B8042300001
--
DURMA
19
BRUSH MECHANISM ASSEMBLY
B8032032700
--
DURMA
20
MATERIAL TABLE ASSEMBLY
B8033190000
105
DURMA
494949101
49
ORIGINAL GUIDE
The rear view of the machine
Figure -2.14 Piece number
PIECE NAME and STANDARD NUMBER
Figure / Code Number
Weight KG 80
COMPANY / CERTIFICATE YILMAZ REDÜKTÖR/CE YILMAZ REDÜKTÖR/CE DURMA
21
MAIN MOTOR
9170001460
22
DRIVING MOTOR
3300102631
23
FIXED CLAMP GUARD
B8043020900
--
24
MATERIAL DRIVING REDUCER GUARD
B8043021500
--
DURMA
25
DIRECTION CHANGING BOX ASSEMBLY
B8043020400
--
DURMA
26
MANUAL MULTIPLE CUTTING APPARATUS
B8043021600
--
DURMA
27
LIFTING CYLINDER ASSEMBLY (DCB 560)
B8042070000
28
HYDRAULIC UNIT 1,1 KW 3,2CC 12LT TANK
3605100073
29
CENTRIFUGE PUMP BP12
3434000398
30
ROLLER TENSIONING GUIDE
505050101
B8032031202
25
16 ---
DURMA HYDRO PACK/CE DEGISIM MOTOR DURMA
50
ORIGINAL GUIDE
Piece number
PIECE NAME and STANDARD NUMBER
Figure / Code Number
Weight KG
COMPANY / CERTIFICATE
31
ROLLER TENSIONING CYLINDER
B8042030102
--
DURMA
32
CLAMP TIGHTENING CYLINDER
B8042020200
--
DURMA
33
ROLLER TENSIONING ROTATION WHEEL
B8042032606
--
DURMA
34
CABLE CHANNEL
3770002145
--
CPS / CE
35
GUIDED BODY INTERMEDIATE COVER
B8042030008
--
DURMA
36
UPPER BRIDGE
B8042050000
--
DURMA
37
CHAIN TENSIONING GEAR 2
B8043020108
--
DURMA
38
CHAIN DOUBLE SEQUENCED 1/2
0803000042
--
ZIMAS/CE
39
CHAIN TENSIONING GEAR 1
B8043020106
--
DURMA
40
CAM SHAFT
B8043020105
--
41
ROLLER TENSIONING CYLINDER GUARD
B8042030007
--
CPS50.75.BO
THE DETAILS OF THE LENGTH AND HEIGHT ADJUSTMENT APPARATUS
Figure -2.15 Piece number
PIECE NAME and STANDARD NUMBER
Figure / Code Number
Weight KG
DURMA DURMA
COMPANY
1
LENGTH ADJUSTMENT SWITCH PIN
B8004100004
--
2
LENGTH ADJUSTMENT SWITCH SHELL
B8004100005
--
3
LENGTH ADJUSTMENT SWITCH CONNECTION PIECE
B8004100003
--
DURMA
4
SWITCH CONNECTION PIECE
B1010010013
--
DURMA
5
LENGTH MEASUREMENT RULER TAG ETK:8002-015
3903013075
--
SAHELLER/CE
515151101
51
ORIGINAL GUIDE CONTROL PANEL 0 1 2
9
13
8
15
3
14
7 4
set
6
GE ER N
CY
EM
5
1
12
START
S TO P
2
3
9
10
11
5
4
7
8
6
STOP
GETK.8042.001
Figure -2.16 Piece number 1
PIECE NAME and STANDARD NUMBER START BUTTON
Figure / Code Number
Weight KG
COMPANY / CERTIFICATE
3300700470
--
SIEMENS / CE SIEMENS / CE
2
STOP BUTTON
3300700490
--
3
ALARM LAMP
3301400102
--
SIEMENS / CE
4
WATER PUMP SWITCH
3300700355
--
HIDROPAR/CE
5
SAW UPWARD BUTTON
3300700450
--
SIEMENS / CE
6
SAW DOWNWARD BUTTON
3300700450
--
SIEMENS / CE
7
BACK DRIVING BUTTON
3300700450
--
SIEMENS / CE
8
FORWARD DRIVING BUTTON
3300700450
--
SIEMENS / CE
9
MANUAL / AUTO SELECTIVE BUTTON
3300700450
--
SIEMENS / CE
10
CLAMP RELEASING BUTTON
3300700450
--
SIEMENS / CE
11
CLAMP TIGHTENING BUTTON
3300700450
--
SIEMENS / CE
12
EMERGENCY STOP BUTTON
3300700040
--
SIEMENS / CE
13
COUNTER
3303910170
--
EMKO / CE
14
DIGITAL EPM 3790
3303910171
--
EMKO / CE
15
HYDRAULIC SPEED ADJUSTMENT VALVE
3427050195
--
HIDROPAR/CE
FIXED CLAMP MAIN PIECES
525252101
52
ORIGINAL GUIDE MAIN PIECES OF THE MOVABLE CLAMP
MAIN PIECES OF THE CHIP CONVEYOR
Figure -2.17
Piece number
PIECE NAME and STANDARD NUMBER
1
WELDED ASSEMBLY OF THE CONVEYOR
2
CONVEYOR MOTOR REDUCER
3 4 5
Figure / Code Number
3300102626
DURMA YILMAZ RED./CE
HELIX ASSEMBLY
8052.07.01.20
DURMA
KONVEYOR REDUCER FLANGE
8052.07.00.07
DURMA
6206 -BEARING
3603600022
ORS / CE
6
GRAPHITE BUSH PAP 3545 P10
3603510314
BUSHING/CE
7
M8 x 20
DIN 912
DURMA
535353101
8052.07.01.00
COMPANY / CERTIFICATE
53
ORIGINAL GUIDE 2.8 Standard and optional accessories in the machine 2.8.1 Standard accessories Hydraulic Material Tightening: The fixation of the materials, which are to be cut, between the clamps is one of the most important factors for the cutting process. The material, which is tightened by the hydraulic cylinder driven clamps, is fixed during the cutting process without being loosened. Cutting Speed which can be Adjusted in a non-gradual manner: For obtaining ideal cuttings, the cutting speed should be adjusted to a suitable value. When the cutting speed is low or high, the cutting results are bad and the blade life is decreased. The cutting speed can be easily adjusted to the desired speed through the digital display on the control panel in a non-gradual manner. Motorized 90° Rolled Driven Clamp: This is the simplest and most rapid material driving system among the automatic models. All of the rolls are driven by a chain from the motor outlet. It provides great advantages in all of the general purpose cuttings. Bimetal Bandsaw: As a standard, in all of the bandsaw machines, one bimetal bandsaw is given so as to be compliant with the general usage. When desired, different models or the blades in tooth step can be provided as extra. Cooling System: Thanks to the strong centrifuge pump, in watery sections, water-based borate oil is adjusted with the desired flow rate and sent to the cutting region and to the blade bearings. The machine is delivered so as not to have borate oil. Cutting Height Adjustment: The positioning of the blade at a substantial height according to the height of the materials to be cut, provides great time saving by decreasing the waiting time in the cycle particularly in serial cuttings. Bearing and Carbide Type Blade Bedding: When a suitable saw blade is used, the perpendicularity and the glibness of the cutting mostly depend on the blade bearings. Thanks to the carbide metals which contact with the lateral surfaces of the blade so as to have a suitable space and parallelism and thanks to the bearings on the back surface, cuttings with ideal perpendicularity and glibness are realized. Thanks to this, the blade and material costs and the after-cutting labor are minimized. Chip Brush: During the cutting process, the cleaning of the chips existing between the teeth of the blade is very important for the life of the blade. These chips are substantially cleaned by the chip brush rotating by means of the blade effect. The chip accumulation around the saw body is prevented. Hydro-mechanical Blade Tensioning: During the manual tensioning of the blade, it provides the ideal tension to be seen on the manometer. It stops the system in case the blade is broken. Mechanical Upper Press: In the multiple cutting of the materials in binding form, the packet is prevented from being distributed since the roll, which has bearing and which is adjusted by hand, applies pressure from above.
545454101
54
ORIGINAL GUIDE Electrical Length Adjustment: In automatic models, the length adjustment of the material to be cut is realized by fixing, by hand, of the mechanic stop in the desired dimension up to 600 mm. In serial cuttings, rolled driven clamp drives the material up to the stop and when it contacts with the stop, the desired length dimension is obtained, and the driving process ends and the cutting process begins. When the cutting is finished, the piece falls and the cycle is repeated. Piece counter: In automatic models, the number of the material to be cut is entered and serial cuttings are provided to be realized. Besides, it also illustrates the alarm and cutting data regarding the machine. 1200mm Material Table: By means of the bearing type rolled material table existing in the inlet or outlet of the machine, the material to be cut can be easily driven. One table is provided together with the related machine as a standard. Since the additional tables can be added one after the other, longer materials can also be supported.
2.8.2 Optional accessories Hydraulic Blade Tensioning: It provides the blade tensioning process to be realized through the control panel without human force. When ideal tension is provided, the tensioning process is ended. It stops the system in case the blade is broken. Motorized Chip Brush: The chips remaining between the teeth of the blade during cutting should be cleaned for the lifetime of the blade to be longer. By means of motorized chip brush, these chips are substantially cleaned. Chip accumulation around the blade body is prevented. NC Control System: In automatic models, operation of all of the functions becomes easier with the programming of the length, cutting number and other parameters through the touch-screen. The measuring of the material, which is pressed between the roller driven clamps, by the encoder, and cutting of said material in the desired length are provided without the need for the switch type automatic length stop system. Chip Conveyor: Particularly during the cutting of full materials, the output chip amount is excessive and it has to be cleaned frequently. By means of the motorized chip conveyor, the accumulated chips are discharged from the machine. Laser Marking System: It facilitates the length adjustment of the material to be cut. From the laser line reflected onto the material surface, without the need for the front surface of the bandsaw, the length dimension and the point where the material will be cut can be easily seen. By positioning the saw blade upwardly from the material, during the advancing of the material, it is prevented from being damaged. This facilitates operation in half automatic models and particular cutting processes. Automatic Cutting Pressure Control: In order to provide ideal cuttings, the adjustment of the suitable lowering speed is very important. If the lowering speed is low or excessive, the cuttings are deteriorated and the blade lifetime is shortened. By means of automatic cutting pressure control, the blade is provided to function with ideal load during the cutting process, the blade lifetime is
555555101
55
ORIGINAL GUIDE engthened. Micro-spray Cooling System: Particularly during the cutting of walled materials (Pipe, Profile, U, I, H, L), it is used instead of the borate oil which is used for cooling the heated blade. By spraying air and micronized particular cutting lubricant mixture to the tooth ends of the saw, the chips on the teeth can be removed in an easier manner, the heating formed on the teeth is decreased and the blade lifetime is increased. It is ecologic, besides, it minimizes the borate oil costs.
2.8.3 Particular solutions
For cutting long materials easily, order Material Tables with particular dimensions.
Contact with the manufacturer company for Different Clamp Height Solutions.
565656101
56
ORIGINAL GUIDE
2.9 Noise 2.9.1 Noise measurement levels
♦
When the machine is idle......55......dB
♦
When the machine is operating with load......58.....dB
♦
Water pump......52......dB
NOTE: The measurements are realized according to the EN ISO 11202 noise measurement standard in the direction of the standard EN 12100.
The noise limit is designed to be at the minimum level. The design is prepared in the direction of the belowmentioned factors:
Figure -2.19
Operator position measurement point (5) •
In the rollers where the blade is bedded, bearings and guides, which function without noise, are used.
•
The flexible hoses are insulated from the pump and manifold assembled to the machine.
• In case the valves function during pressure, hydraulic circuit designs are selected which prevent the noise which may be formed as a result of the hydraulic. •
Couplings are used between the motor and the pump which prevent vibration.
575757101
57
ORIGINAL GUIDE 2.10 Standards used in saw design In the design of DCB series columned type machines, the TS EN 13898 standard is used. During the assembly steps, by using certificated safety members compliant with the standards, operating conditions with “0” accident with high safety are desired to be obtained. EN 13898
Machine Safety – Simple designs, design for the general principles Item 1 : Simple terminology, methodology.
EN 292-2
Machine Safety - Simple designs, design for the general principles
EN 292-1
Item 2 : Technical principles and properties.
EN 418
Machine Safety – Emergency stop fixtures and functional pieces.
EN 953
Machine Safety - Traceability (fixed, movable).
EN 982 EN 60204-1
Machine Safety – Safety rules for the fluid systems and pieces – Hydraulic. Machine Safety – Electrical equipment of the industrial machines. Item 1: General rules.
Figure 2.20
585858101
58
ORIGINAL GUIDE PART 3 - INSTRUCTIONS FOR MACHINE TRANSPORTATION 3.1 Transportation of the machine
Q : 2450 kg.
D
A C
B Figure 3.1 There are four carrying hooks on the machine. This is illustrated as A, B, C and D in Figure 3-1. Before starting the carrying process, fix the movable members (clamp, rotating table, electrical panel, etc.). Take the guided body to the bottom position. Fix the members which can be rotated. Do not carry machine members like material table, which are used externally, together with the machine. Carry these members after the machine is carried and placed. Connect the hoist hook and carrying hooks by means of a firm rope, and afterwards, place the machine to a suitable place inside the plant.
Attention!
During the carrying of the machine, be sure that the machine is positioned so as not to give damage to the machine and to the environment.
While positioning the machine, taking into consideration that the piece to be cut is to be driven, be sure that the machine is positioned so as not to give damage to the personnel, to the machine and to the environment.
Attention! During hoist movement and during carrying, there should not be any person under the carried material and comply with the general carrying rules.
595959101
59
ORIGINAL GUIDE TASIMA SEKLI WEIGHT : 2600 Kg.
Figure 3.2
• During transportation and storing, in order for our machines not to be affected from the environmental conditions, our machines are wrapped by nylon folio. • When the machine arrives at the place where it is to be operated or stored, tools like crane, hoist, lifter, etc. should be ready and the region where the machine will be placed should be completed and the environmental conditions of the region where the machine will be placed should be suitable. • On the concrete where the machine will be installed, there should not be cracks and spaces. • Before bringing the machine to its final position, check the anchorage bolts, be sure these bolts are in the correct place. Balancing bolts should be lubricated and they should be placed on the ground with the whole length.
Attention! Before beginning the carrying process, fix the movable members. Take the guided body to the lowest position. Fix the rotatable members.
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60
ORIGINAL GUIDE 3.2 REMOVING THE PACKAGE After placing the machine to its place, take it from the package thereof carefully. During the removal of the package, do not give damage to the machine.
PART 4 - STORING CONDITIONS If the machine will not be used for a long time: •
Remove the saw blade and preserve it.
•
Empty the hydraulic lubricant.
•
Empty the cooling liquid.
•
Clean the dust and chips on the machine.
•
Lubricate with protective lubricant.
•
Protect the machine from excessive sunlight.
•
Storing in open area (in rainy environment) should be avoided. The valve sockets may be damaged or the electrical system may be damaged.
Package the machine so that dust does not enter.
Attention! If the machine will not be used for a long time, keep it in packaged form in a dry environment.
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ORIGINAL GUIDE PART 5 - MACHINE INSTALLATION INSTRUCTIONS 5.1 The working area of the machine For machine installation, prepare the region illustrated by dashed lines in Figure 5-1. The area, which you determine the general borders, will be the safe operating area of your machine. While operating on the machine, there should be no person inside these areas. The length of the material you cut can be long. Determine the operating area by giving attention that the area, the material will be loaded to the machine, is at least equal to L + 500. If possible, leave the feeding area open. The balance bolts of the machine should be supported by suitable metal pieces. As can be seen in Figure 5-2, the machine should be fixed to the ground by anchorage bolts. Prior to fixation, the concrete should be made compliant to the machine. Moreover, using bolts with the required sizes and quality, this process can be realized. The machine should be checked by means of sensitive balance apparatus (water balance or digital balance). The recommended balance planes are the surfaces on which the clamp functions. The rear material table is balanced by balancing the material table onto the lower surface whereon the clamps function. The balance of the machine is adjusted by the tightening and loosening of the bolts which are placed separately in each leg. THE BODY OF THE MACHINE SHOULD NOT BE SUBJECTED TO BE TWISTED IN ANY CASE. 5.2 Machine installation
THE MAT ERI AL TO BE CUT
THE CUT MATERIAL + 500
Figure 5.1
Attention! The length of the material to be cut should not be greater than the length of the material table.
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ORIGINAL GUIDE 5.3 Machine placement
NUT M12 DIN 934
BOLT M12x30 DIN 933
WASHER
A
SHEET PLATE CONCRETE ANCHORAGE BOLT
A DETAIL Ø
Figure 5.2
Attention! The machine should be installed by trained personnel.
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ORIGINAL GUIDE 5.4 Electrical connections
Connect the machine to the main supply by means of standard electrical cables. The machine is arranged with respect to 3 phase main voltage. The cable input is through under the electrical panel, the cable ends should be connected to the terminals illustrated in the electrical schema. The electrical connections of the machine should be realized by qualified personnel. 1. In order to realize a correct electrical connection, first of all be sure that the main switch of the machine is closed. Afterwards, realize 3 phased cable and grounding connection. 2. Connect the L1, L2, L3 and N and PE end of the cables to the terminal inside the electrical panel. 3. After you connect the cable ends, apply power to the panel. If the connection is correct, bring the main switch on the electrical panel from “0” to “1” position (it is on the control panel). 4. Bring the switch numbered 1 on the machine control panel (Figure 5-3) from “0” to “1” position. The light of the screens should turn on. If the screens do not turn on, this shows that there is problem in the electrical connection. By changing the places of the cable ends, the machine should be COMPLETELY INSULATED and the phase of the machine should be interrupted and the connections should be checked. 5. After the screen is turned on, press the button numbered 2. The hydraulic pump operates. Now the machine is ready for functioning. After you observe that the blade functions after pressing the button numbered 3, stop the blade by pressing the button numbered 4. 6. Panel feeding voltage is 24 volt; Solenoid coil feeding voltage is equal to 24 DC. Each solenoid coil adjustment is connected to the circuit by means of separate relays. Local (coming to the machine) voltage should be checked by assessing the transformer and the main motor voltage. Connect the suitable supply cable to the machine and apply power after checking. 1
2
3
4
Figure 5.3
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ORIGINAL GUIDE 5.4.1 Motor direction Cutting motor will be seen when observed from the rear of the machine. The rotation direction of the cutting motor, which rotates the cutting blade, should not be changed. In order for the teeth on the blade to realize cutting, the teeth should face the motor side and they have to rotate towards the motor. Material feeding motor is adjusted so as to be able to rotate in both directions. For feeding the material, the clamps should be tightened. In order to be able to realize cutting in the desired size, the newly designed driving group facilitates the cutting process for the user. Check the rotation direction of the machine motors.
CUTTING MOTOR DIRECTION
BLADE DIRECTION
DRIVING MOTOR DIRECTION
Machinenin
Figure 5.4 5.4.2 Motor current values kW
q HP
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A
A
mm²
q A
A
mm²
q A
A
mm²
q A
A
mm²
q A
A
mm²
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ORIGINAL GUIDE 5.5 First checks All of the sensitive adjustments of the machine are realized by qualified personnel in our company in the final control step. The electrical powering connections are described in the previous title. Though, check the belowmentioned items. 5.5.1 Cooling liquid Take borate oil, which is equal to 10 % of the depot capacity, and take water, and mix the borate oil and water inside a vessel substantially. Exemplary Application: For a depot of 60 liters, mix 6 liters of borate oil and 54 liters of water. Pour the prepared mixture to the grid holes on the chip box carefully. While filling the cutting liquid, be careful not to pour the liquid outwardly. Carefully pour the 60 liters of cutting liquid, which was prepared outside beforehand, to the machine pool. Afterwards, take the cooling pump switch, which is illustrated by number 3 in Figure 5-3, to the right position. Be sure that the cooling water is pressed by the related pump. Afterwards, take the cooling pump switch to the left position and interrupt water flow. After checking that the cooling water pump functions in a correct manner, bring the saw to the upper border position in the plant adjustment by pressing the saw upward button which is mentioned in the previous title. 5.5.2 Hydraulic Unit The hydraulic unit comprises hydraulic depot and valves (Figure 5-5). The hydraulic unit, which does not occupy much space in the machine, provides high efficiency and it provides the hydraulic of the machine.
Hydraulic Depot capacity is 12 liters.
Figure 5.5
Attention! Check the grounding connection of the hydraulic power unit. Check the lubricant level. If it is missing, fill it.
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Realize the hydraulic level check and the filling process from here.
Realize the pressure adjustment from here.
Figure 5.6 The power unit comprises three units: 1. Electrical motor 2. Solenoid valves 3. Tank (Hydraulic Depot) The electrical motor has 3 synchronized types or single-step normally operating B14 type or continuous unshielded version (model). DC, functioning with 12 and 24 volt, serves the valve block for the front shield of the motors. The solenoid members are cartridge type. Their coils can function with 12, 24 V DC voltages. And 110, 220 V Rac, Binders are under DIN 43650. 5.5.3 Hydraulic Unit Cleaning The cleaning of hydraulic unit is realized by cloth fabric. Other members can not be used. The fabric should not be dispersed onto the surface. Once a year, the lubricant in the tank should be cleaned and moreover, the tank should be cleaned. The lubricant change should be realized in the following manner. The pressure in the system is discharged. The electrical connection of the hydraulic unit is interrupted. The pipe (tube) is removed. The hydraulic unit screws are removed by means of a screwdriver. The unit is placed vertically on the tank. The repairing screw is removed and the tank elbows are placed again. The electrical motor is placed together with the center block. The old lubricant is discharged. The tank inner surface is cleaned. In addition to this, the suctioning filter is also cleaned. The electrical motor with center block is cleaned and afterwards it is placed inside the tank. The repairing screw and the elbow are screwed. The assembled unit is put into operating position. The mentioned amount of hydraulic lubricant is carefully put into the tank through the opening illustrated in Figure 5-6. The air hole should be tightly closed. The pipe (tube) is assembled. And the hydraulic unit is joined with the electrical motor.
Attention! Operation using dirty oil decreases the lifetime of the machine.
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5.5.4 Hydraulic Unit pressure adjustment The pressure adjustment in the hydraulic unit is realized by the RV08-2A valve. The pressure adjustment should be realized through the place illustrated in Figure 5-6. A pressure adjustment is assembled to part “P”. The adjustment screw is removed. The adjustment screw should be removed completely. The hydraulic unit is operated and the adjustment screw is made active until the desired pressure level is reached. Afterwards, the adjustment screw is locked.
Attention! While realizing pressure adjustment, look at the pressure tag. Never exceed the pressure mentioned on the machine.
PART 6 – INSTRUCTIONS FOR COMMISSIONING THE MACHINE 6.1 Commissioning
1
2
3
4
Figure 6.1 For testing the hydraulic system, be sure that the saw is in the top position and be sure that there is no material between the clamp and the saw. Turn the machine turning-on button, which is illustrated by number 1, towards right and take it to the final position. Press the “operate pump” button illustrated by number 2. Check if the hydraulic system operates. Press the “operate cutting motor” button illustrated by number 3, and be sure that the bandsaw turns in the correct direction – towards right when viewed from the front side. For stopping, press once to the stop button illustrated by number 4.
Attention! For the failures checked, look at the Probable Failures, Reasons and the Repairing Routes part.
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ORIGINAL GUIDE
6.2 Powering Connect the R, S, T phases of the supply to the L1, L2, and L3 connectors inside the electrical panel by means of 5x2.5 mm2 cable. During the connections, be sure that the supply switch is closed. Be sure that you connect the protective grounding of the plant to the yellow green grounding connector of the bench. After taking the required safety precautions, bring the supply switch to the open position. Afterwards, bring the main switch on the electrical panel cover of the machine to 1 position. If the power connections are realized in a correct manner, the lights on the control panel will turn on.
12
10
13
E R GE N
CY
EM
set
1
11
START
STOP
2
3
Button numbered 9
9
4
5
7
8
6
Button numbered 5
STOP
GETK.8042.001
Figure 6.2 6.3 Confirmation of the machine The numbers, which exist on the speed control device and on the counter illustrated by 12 and 13, appear on the screen. Turn the button numbered 9 towards left, and take it to the manual position, and press the saw upward button illustrated by number 5. When this button is pressed, if the saw is lifted upwardly, the connections are correct. Otherwise, the phases are connected in an inverse manner. Interrupt the power supply and change the cable ends in the L1 and L2 connectors. When the machine is lifted upwardly, it will stop at the upper limit when it contacts with the switch which is illustrated in Figure 6-3 and which exists on the guided body in the upper reference point. This process shows that the machine is operating in a correct manner and that the safety switch operates well.
Figure 6.3 696969101
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ORIGINAL GUIDE PART 7 – USAGE INSTRUCTIONS
7.1 User’s region • • • •
The machine is designed so as to be operated with one (1) operator. Do not approach the movable points while the machine is in operation. Comply with the values mentioned in the safety distance dimension (Figure 5-1). While the machine is in operation, the region where the operator has to exist is given in Figure 7-1. If the user exists in these regions, accidents may occur. Since the cutting table, which moves downwardly and upwardly, is close to the electrical panel, if the user approaches his hands towards the rear of the panel, accidents may occur. Therefore, do not approach hands to the rear of the electrical panel.
Figure 7.1
Attention ! The electrical panel can be on the right or on the left depending on the machine model. This does not change the dangers and warnings above.
Attention! IN CASE OF AN INJURY, A DOCTOR SHOULD BE CALLED OR THE INJURED PERSON SHOULD BE BROUGHT TO A HEALTH CENTER EMERGENTLY.
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ORIGINAL GUIDE 7.1.1 Prior to cutting In the cutting table on the electrical panel, the suitable cutting conditions for the material to be cut are described. In this table; the most suitable cutting speed, the blade type to be used, tooth number, and if watery cutting can be realized or not can be seen. Prior to cutting, the blade bearings should be adjusted according to the material to be cut. Take the blade bearing to the desired position by turning the turning wheel existing on the arm and tighten the fixation screw. Be sure that the blade bearing does not hit the clamps. Do not forget that if the bearing is close to the material, the cutting will be realized in a steeper and smoother manner. 7.1.2 Cutting
10
11
13
1
2
12
7
8
3
Figure 7.2
5
6
4
9
1. By turning the button 1 switch in Figure 7-2, turn on the machine and operate the pump using button 2. 2. By taking the blade to the upper position by means of Button 3, carefully place the material to be cut between the clamps. 3. Tighten the clamp (Button 4) without deforming the material to be cut; and using the driving buttons, adjust (Button 5-6) the length of the material to be cut. 4. By pressing the start button illustrated by 7, operate the cutting motor. Observe the movement of the blade. 5. According to the type of the material to be cut, turn the water motor functioning switch, which is illustrated by 8, to the right, and thereby provide the flowing of the cooling water. Adjust the water flow through the valves on the blade bearings and on the clamp. 6. By pressing the button illustrated by 9, check the lowering of the saw head by means of the saw speed adjustment valve illustrated by 10. 7. Adjust the rotation speed of the bandsaw by means of the potentiometer on the saw speed adjustment device illustrated by 11. 8. Realize the material cutting using the adjusted cutting speed and the lowering speed. 9. In case of any failure, press the stop button illustrated by 12, in case of an emergency, press the emergency stop button illustrated by 13.
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ORIGINAL GUIDE 7.1.3 Language Selection For selecting the screen language as English or Turkish; use the + button in manual mode. When pressed once, the other language will be selected. 7.1.4 Counter usage
I
K
1.
2.
G
M 3.
N
Attention!
L
J
H
There are six buttons in the counter for entering the target number. These are illustrated by G,H,I,J,K,L. G is used for changing the number in the units digit, H is used for changing the number in the 10’s digit, I is used for changing the number in the hundreds digit, J is used for thousands digit, K for 10.000’s digit, and L is used for changing the number in the 100.000’s digit. When these buttons are pressed, the number always increments by 1. If it is 0, it becomes 1, if it is 1, it becomes 2…. When pressed if the number is 9, it returns to 0 again. The reset button illustrated by M in the counter is used for resetting the number of cuts. The LOCK button, which is illustrated by N in the figure, cancels the resetting button. When the LOCK button is pressed again, the resetting button can be used.
The hydraulic clamps can be tightened and loosened only when there is no cutting process. If there is no material between the clamps, the following warning message appears on the screen.
7.1.5 Digital potentiometer
1. Press the Set button once for a short time. The revolution (as revolution/minute) on the screen will start flashing. 2. Using the ? and s buttons, adjust the revolution speed. 3. In case the ? and s buttons are pressed, firstly the 0.1’s, afterwards the 1’s, afterwards the 10’s digit will increase or decrease. 4. Confirm this value by pressing the set button again. 5. If the set button is not pressed for confirmation, it will turn to the prior revolution value 10 seconds later.
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ORIGINAL GUIDE 7.2 Operating the machine 7.2.1 Manual cutting 0 1
EM
8
12
3
ERGEN
14
CY
2
9
1. Take the machine to the manual cutting mode by turning the button 3 to the left.
15
13
7 4
6 5
S T OP
2. In manual operation, if there is material between the clamps and if there is no alarm, the following screen will appear:
11
1
3
5
6
9
4
7
8
10
START
2 STOP
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3. In case of a failure, in both manual and automatic mode, the following screen will appear.
As can also be seen from above, the alarm cases are the following: a. The emergency stop button is pressed, b. Inverter warning, c. The thermal protection of the cooling and driving motors (overloading) and d. The blade is loosened. 4. In case where the blade is loosened, tighten the blade by turning the blade tightening unit and observing the blade pressure if the blade is mechanic; and if the blade is hydraulic, tighten the blade by means of the button numbered 11. 5. In hydraulic blade tightening, pressure switch with hysteresis is used. If you tighten the blade with 120 bars, the alarm message on the screen will disappear. On the other hand, when the pressure is 70 bars, the blade will loosen and it will give alarm. Hydraulic blade tightening can only be realized in the manual mode and when the cutting motor is not functioning. 6. By pressing the blade upward button illustrated by 9, lift the blade head upwardly. 7. By pressing the downward button illustrated by 10, lower the head in a hydraulically controlled manner. When the blade head is above the material, it will move downwardly in a rapid manner. When the contact arm (blade) contacts with the material, the valve, illustrated by 12, will be activated and it will move downwardly in the adjusted low speed (both during the cutting process and when there is no cutting).
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0 1
8
3
EM
9
12
ERGEN
14
CY
2
8. Press the forward button (illustrated by 8), and feed the material forward on the clamp. Press the button which is illustrated by 7, and take the material back.
15
13
7 4
6 5
S T OP
11
1
3
5
6
9
4
7
8
10
9. If watery cutting is to be realized, turn the water motor button (illustrated by 4) to the right and thereby the cooling water flows. Adjust the water flow through the valves on the flexible hose and the rectification arm.
START
2 STOP
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10. For starting the cutting process, press the “start cutting motor” button illustrated by 1. The cutting process will begin only when there is no contact between the material contact arm (blade) and the material. 11. In case of a failure, press the stop button illustrated by 2, when there is a more emergent case, press the emergency stop button illustrated by 13. 12. Adjust the hydraulic lowering speed of the head by means of the valve illustrated by 12. 13. Adjust the rotation speed of the bandsaw by means of the digital potentiometer illustrated by 15.
Attention! The cooling liquid will only flow while the cutting motor is functioning during the cutting process. Take precautions for preventing the sloshing of the cooling liquid.
7.2.1 Automatic cutting
1. Take the machine to the automatic cutting mode by turning button 3 to the right. 2. During automatic operation, if there is material between the clamps, and if there is no alarm condition, the following screen will appear.
3. Adjust the length adjustment apparatus (illustrated in the figure) according to the size of the material to be cut. For this reason, use the ruler illustrated by D.
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4. After adjusting the length to be cut, enter the number, you desire to cut, through the smart relay. In the
5. 6.
7. 8. 9.
adjustment of the numbers to be cut: a. + button is used for increasing the number to be cut, b. - button is used for decreasing the number to be cut, c. OK button is used for resetting the number being cut and the number to be cut, d. “A” button is used for passing from the units digit to the 10’s digit and to the hundreds digit, in the numbers to be cut, e. The B button is used for realizing the inverse of the function of the A button. f. When the ESC button is pressed for a short time, the screen is illuminated. If watery cutting is to be realized, turn the water motor activate button (illustrated by 6) to the right and the cooling water flows. Adjust the water flow through the valves on the flexible hose and the rectification arm. For starting the cutting process, press the cutting motor activate button (illustrated by 1). If the head is not in the upper position, it will automatically rise to the TOP limit, and afterwards, it will start the cutting process. However, this is valid for the first start cutting. In the second and in the next cutting processes, 0.5 seconds after the material is released from the contact arm, the other processes will continue. In case of any failure, press the stop button illustrated by 2, when there is a more emergent case, press the emergency stop button illustrated by 13. Adjust the hydraulic lowering speed of the head by means of the valve illustrated by 12. Adjust the rotation speed of the bandsaw by means of the digital potentiometer illustrated by 15.
Attention! DCB-A Machine does not realize angled cutting. Do not try to realize angled cutting. Note: For the angled cutting machines, contact with the manufacturer.
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ORIGINAL GUIDE 7.2.3 Siemens Simatic Panel
DCB-A 560 01/07/2010 08:00:00 www.durmazlar.com.tr
ALARM PAGE IT SHOWS THE ALARMS WHICH THE MACHINE GIVES OUT AT THAT MOMENT AND IN THE PAST
The figures on the guide can be different from your machine.
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ORIGINAL GUIDE MAIN MENU
DCB FA 330
10:59:59 AM
THE PASSAGE TO THE DESIRED PART CAN BE PROVIDED
IT IS USED FOR RETURNING TO THE HOME PAGE.
WORKPAGE IF THE BUTTONS ARE FLASHING, THE CLAMPS ARE TIGHTENED. IF THE BUTTONS ARE FLASHING, THE SAW HEAD IS UPWARDS. CLAMP THIS IS THE PAGE WHERE WE CAN SEE THE PROCESSES OF THE MACHINE. WE CAN SEE THE NUMBER OF CUTS, THE TOTAL NUMBER, THE OPERATING MODE AND THE FRACTION OF THE PROGRAM WHICH IS FINISHED. IN MANUAL MODE, IN ORDER FOR THE MACHINE TO START, THE FRONT COVER HAS TO BE CLOSED, THE BLADE SHOULD BE IN TENSIONED STATE, THE BLADE HEAD SHOULD BE IN THE UPPER LIMIT AND THE CLAMP SHOULD BE IN THE TIGHTENED POSITION.
PROTECTION LOCKING THIS IS USED FOR PREVENTING THE USAGE OTHER THAN THE OPERATOR.
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CUTTING PROGRAM PAGE THIS IS USED FOR FORMING A NEW PROGRAM, NAMING, SAVING, CLEARING OF ALL THE TABLES AND FOR REACHING THE PROGRAMS WHICH WERE SAVED BEFORE.
CUTTING PROGRAM PAGE .
SINGLE MATERIAL FEEDING PAGE DCB FA 330 10:59:59 AM
FEED BACK: THE BUTTON FOR FEEDING BACK THE ENTERED MATERIAL FEED FORWARD: THE BUTTON FOR FEEDING FORWARD THE ENTERED MATERIAL IT IS USED FOR TAKING THE MOVABLE FEEDING GROUP TO THE FORWARD REFERENCE POINT. IT IS USED FOR TAKING THE MOVABLE FEEDING GROUP TO THE REVERSE REFERENCE POINT ON THIS PAGE, FORWARD OR BACKWARD FEEDING GROUPS ARE POSITIONED, WHICH ARE IN NUMBER EQUAL TO THE ENTERED NUMBER.
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USER ADJUSTMENTS THIS IS THE PART WHERE THE LANGUAGE SELECTION, MEASUREMENT UNIT, CLOCK ADJUSTMENT AND SCREEN ADJUSTMENT ARE REALIZED.
USER ADJUSTMENTS THIS IS THE PART WHERE MULTIPLE CUTTING AUTOMATIC TURNING OFF ADJUSTMENTS ARE REALIZED.
USER ADJUSTMENTS THE AUTHORIZED PERSON ENTERS TO THIS PAGE USING THE ADMIN PASSWORD. THE OFFSET AND COEFFICIENT VALUES ARE ADJUSTED. OFFSET: IF THERE IS CONTINUOUS AND FIXED DEVIATION IN THE LENGTH FEEDING PROCESS, THE DEVIATION VALUE IS WRITTEN TO THIS LINE AND THE FAILURE IS ELIMINATED. COEFFICIENT: IF THERE IS CONTINUOUS LENGTH INCREASE AND DECREASE IN THE LENGTH FEEDING PROCESS, THE COEFFICIENT VALUE IS WRITTEN TO THIS LINE AND THE FAILURE IS ELIMINATED
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ORIGINAL GUIDE
USER ADJUSTMENTS THIS IS THE PAGE WHERE THE CUTTING SPACE THICKNESS INCLUDING THE MATERIAL BACWARD FEEDING DISTANCE AND THE BLADE OUTER CROSSES ARE ADJUSTED AFTER THE CUTTING PROCESS FINISHES.
USER ADJUSTMENTS SAW ROTATION: THE SELECTION OF DOWNWARD OR DOWNWARD-UPWARD OPERATION OF THE SAW ROTATION SAW TENTIONING: IN CASE OF BLADE BREAKAGE OR BLADE LOOSENING, THIS IS THE SELECTION OF MACHINE STOP OR MACHINE CONTINUING OPERATION. (FOR SAFETY, STOPPING IS PREFERRED.) THIS PROVIDES THE POSITIONING SPEED ADJUSTMENT OF THE MOVABLE GROUP IN AUTOMATIC OR MANUAL MODE.
USER ADJUSTMENTS THIS IS THE PAGE WHERE THE WAITING DURATIONS IN THE CYCLE ARE ADJUSTED. THE ENTERED VALUES ADJUST THE WAITING DURATION AFTER THE MENTIONED PROCESSES.
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USER ADJUSTMENTS THE TIGHTENING PROCESSES OF THE FIXED CLAMPS IS REALIZED BOTH IN TERMS OF PRESSURE AND IN TERMS OF TIME DURATION . IF IT WILL BE REALIZED BY MEANS OF PRESSURE, THE PRESSURE CHOICE IS MARKED. IF IT WILL BE REALIZED BY MEANS OF TIME DURATION, IT IS PROVIDED TO WAIT FOR A TIME EQUAL TO THE ENTERED VALUE. IT LOADS THE FACTORY DEFAULT VALUES.
SERVICE PAGE AFTER THE MACHINE IS COMMISSIONED OR AFTER ANY CHANGE IN THE MACHINE, THE RESET BUTTON IS PRESSED AND THE MACHINE REALIZES POSITIONING. IF THIS PROCESS IS NOT REALIZED WHEN THE MACHINE IS COMMISSIONED, THE MACHINE DOES NOT REALIZE THE DRIVING PROCESS. PANEL SETTINGS: THIS IS THE PAGE WHERE NEW SOFTWARE IS LOADED TO THE MACHINE. IT IS USED FOR RESETTING BY SENDING THE MOVABLE GROUP TO THE REFERENCE BACK.
PLC INPUTS PAGE THESE ARE THE CODES WHERE THE ELECTRICAL EQUIPMENT ON THE MACHINE REALIZE PLC INPUT.
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ORIGINAL GUIDE OPTIONS PAGE THE OPTIONS ON THE MACHONE ARE MADE ACTIVE OR PASSIVE.
7.2.2 Turning off the machine
There is the emergency stop button on the control panel of the machine. The emergency stop button stops all of the movements of the machine in time duration shorter than 1 second. 7.2.3 Restarting the machine which was stopped emergently
1. For restarting the machine which was stopped emergently, first of all, eliminate the reasons for emergency stop. 2. Turn the emergency stop mushroom button on the electrical panel in the counter-clockwise direction, and reactivate it. 3. If it is in the automatic mode, take it to the manual mode and lift the cutting table upwardly. 4. Realize the required controls and check the details like the loosening of the piece which is tightened to the clamp, and like breakage of the blade. 5. If there is no danger and/or there is no failure, you can restart by pressing on the button which provides operation in the desired mode.
Warning! Usage of the emergency stop button continuously in unnecessary cases shortens the lifetime of the motor and the inverter.
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ORIGINAL GUIDE 7.3 Presentation of the buttons
Manual – Automatic Switch Emergency Stop Button
Machine Starting Button
“Operate pump” button
Clamp 1 is closed
“Clamp 1 is active” button
Saw Operating Button Driving Left Button
Saw Upwards Button Driving Right Button
Saw Upwards Button
Clamp opening button
Saw Downwards Button Counter Control Panel
Cooling liquid On/Off Button Speed Adjustment Unit
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ORIGINAL GUIDE 7.4 Clamp usage
Figure M1
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ORIGINAL GUIDE
PART 8 – MAINTENANCE, REPAIRING AND CLEANING INSTRUCTIONS 8.1 Saw Blade Adjustment 1. There are two adjustments of the saw blade in the drive and idle rollers. The first adjustment is realized as in Figure 8-1 by pushingpulling by means of setscrew and bolts existing on the motor flange and thereby the parallelism adjustment is realized.
Figure 8-1
Figure 8-2
2. In case the blade loosens, realize the tensioning process by turning in the clockwise direction by means of the roller tensioning cylinder as in Figure 8-2. Apply the tensioning process until the pressure value of the manometer is between 80-100 bars. 3. If vibrations are formed on the blade during cutting, the blade roller bearings in Figure 8-3 and in Figure 8-4 have to be tightened. By means of the setscrews illustrated below, tighten the shoes which exist inside the roller bearing which houses the blade from two ends and which exists under the rectification arms. (Figure 8-3: left rectification arm, Figure 8-4: right rectification arm)
Figure 8-3
Figure 8-4
8.2 Maintenance information 8.2.1 Daily Maintenance 1. At the end of the day; clean the chips accumulated in the pool, around the clamp, and between the flywheels and the blade bearings. 2. Empty the chip drawer. 3. While the machine is not in use, loosen the blade for providing a long lifetime. 4. While the machine is not in use, be sure that the head is positioned below and there is no material between the clamps. 5. Clean and lubricate the rectification arm and the guide.
Warning! Change the reducer lubricant once in every six months. Clean the electrical components by 878787101 87 applying air inside the electrical panel.
ORIGINAL GUIDE 8.2.2 Weekly Maintenance 1. Check the spaces of the blade bearings. 2. Loosen the blade. Check the bolts and nuts of the flywheels, if necessary tighten them. 8.2.3 Monthly Maintenance 1. Check the hydraulic oil, if missing, add hydraulic oil. 2. Realize leakage tests in the hydraulic valves and hoses. 3. Clean the borate oil depot. 4. Clean the rolls, chain and chain gears in the driver clamp group and lubricate them with grease oil. Tension the chain. 5. Lubricate the flywheel bearings by means of grease oil. Sekil 8-5 1_1 Figure
6. Lubricate the clamp bearings. 8.3 Blade change 1. Turn off the main switch. (Figure 8-5)
!
2.
Open the flywheel sheet cover. (Figure 8-6)
3.
Turn the blade tensioning wheel in Figure 8-7, which will reset the pressure in the manometer, in the counter-clockwise direction and loosen the blade (Figure 8-6). If the tensioning is hydraulic, on the control panel, rotate the Blade Tensioning Button in the loosening direction. (Figure 8-8)
4.
Press the blade downwardly. (Figure 8-8)
Sekil 1_2 Figure 8-6
Figure _5 Figure 8-7
Sekil 1_3
Figure 8-8
Sekil 1_4
Figure 8-8
5. Remove the blade from its bearings. (Figure 8-9) 6. Remove the blade from the flywheel, by means of pressurized air, clean the roller periphery and the blade bearings. 7. Before removing the protective band of the blade you desire to fix, first of all, fix it to the flywheels and afterwards, fix to the housings of the bearings existing on the rectification arms. 8. Be sure that the blade gears face to the left when viewed from the front surface. 9. Rotate the blade tensioning wheel in clockwise direction, if the tensioning is hydraulic, tension it between 80 and 100 bars. 10. Meanwhile, check the pressure in the manometer. Finish the tensioning process, if the pressure is between 80Attention! 100 bars. 11. After the new blade is fixed, do not forget that it will expand as a result of heating. In this case, tighten it again. 12. Use gloves and eye-glasses during blade change. 13. Take into consideration that if the blade is loosened, there may be danger.
Figure 8-9
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ATTENTION! THE BLADE TENSIONING PRESSURE SHOULD NOT BE ABOVE 120 BARS.
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ORIGINAL GUIDE 14. After fixing the blade, remove the protective band on the blade illustrated in Figure 8-10.
Figure 8-10
8.4 Information about the lubricant used in the machine No Lubrication Region Period Lubricant Type ISO Shell ISO HV TELLUS 1 Hydraulic Unit Yearly OEL T46 46 Six OMALA 2 Reducer ISO 320 months 320 Hydro-mechanical TELLUS ISO HV 3 Yearly Blade Tensioning 46 Cylinder 4 Flywheel Bearings, Blade Monthly ISO XMO ALVANIA Six ALVANIA ISO XMO 5 Tensioning Guide months Six ALVANIA 6 Rack gear ISO XMO months Six ISO HV TELLUS 7 Column Bearings months 46 OEL T46 Six ALVANIA 8 Direction Change Box ISO XMO months Liquid EP 0 9 Clamp Lower Bearing Monthly lubricant Liquid 10 Chain Tensioning Gear Weekly EP 0 lubricant Six ALVANIA 11 Drive Chain Gear ISO XMO months Lower Chain Tensioning Liquid 12 Weekly EP 0 Gear lubricant
Mobil MOBIL DTE 15 MOBILGEAR 632 MOBIL
BP BARTRAN HV 46 GR XP 320
MOBIL MOBIL
GREASE GREASE
MOBIL
GREASE
BARTRAN
MOBIL DTE BARTRAN 15 HV 46 MOBIL GREASE PLEX 45
LTX0
PLEX 45
LTX0
MOBIL
GREASE
PLEX 45
LTX0
5
3
2
8
10
11
9 1
Figure 8-11 12
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ORIGINAL GUIDE PART 9 – TROUBLESHOOTING DATA 9.1 Probable Failures Mechanical Failure
The head vibrates during cutting
The cutting Duration is Long
The saw edge does not cut
Reason
Solution
The pressure adjustment is insufficient Blade teeth are broken The blade edge is welded in a faulty manner The flywheel and the rollers are loose The pressure adjustment is insufficient The blade edge is not sharp The blade rotation speed is faulty The correct blade edge is not used The blade edge is connected in a faulty manner Main motor rotates in the reverse direction
Turn the hydraulic speed adjustment valve to the left and open the valve. Change the blade
The cutting pressure is excessive
The cutting is not regular
There is vibration during the cutting process
In NC automatic cutting, the length is not correct
The blade rotation speed is low The blade edge is not sharp The blade is not tensioned The clamp claws are unadjusted The flywheel is abraded The blade bearings can not hold the blade. The blade is rotating very rapidly. The blade bearings are adjusted to be far The blade is not tensioned The material is not placed in a suitable manner. Material driving reducer chain gears may loosen. The belt, connected to the encoder, can be loosened. There can be water leakage in the lower limit switch. The encoder may have a failure
The cutting liquid flow is not sufficient.
909090101
The water level is decreased The valve and the hoses are clogged. The pool and the chip drawer are full
Change the blade Tighten the nuts and bolts Turn the hydraulic speed adjustment valve to the left and open the valve Change the blade Check the tooth direction Check the tags on the flywheel cover Check the tooth direction Check the phase sequence Adjust from the hydraulic speed adjustment valve Use the schema on the flywheel cover Change the blade Tighten the blade Adjust the clamp in a suitable manner. Contact with the dealer Adjust the blade rectification arm so as to be closer to each other Use the schema on the flywheel cover Adjust the blade rectification arm so as to be closer to each other Tighten the blade Place the material in a suitable manner. Eliminate the chain space. Tension the encoder connection plate. Clean and tighten the switch bolts so that water does not enter. Confirm the driven length by tightening the material in manual operation. Add water. Clean with the help of pressurized air. Clean the chips.
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ORIGINAL GUIDE The blade tension is not suitable.
Blade tooth selection is not suitable. The blade is breaking Cutting speed and advancing are not suitable. The directing units at the blade bearings are very tight.
Bring the blade to the ideal blade tension. Select a suitable blade for the material type and the material dimension to be cut. For this, you can contact with the blade dealers or you can contact with the machine technical service. Select the suitable cutting speed and advancing from the blade catalogues used or from the cutting schema on the machine. Loosen the directing units. The ideal gap should be equal to 0.1 mm.
9.2 Inverter failure codes and the descriptions thereof Error Code
F0001
919191101
Contents
High current
Probable Reason
1. Motor power, 2. Short circuit in the motor cable 3. Grounding fault
Things to be done 1. Check if the motor power is compliant with the inverter power. 2. Check if the cable length limits are exceeded or not. 3. Check if there is short circuit and grounding faults in the motor cable and in the motor. 4. Check if the motor parameters are compliant with the used motor or not. 5. Check the resistance of the stator (P0350). 6. Increase the motor revolution raising duration (P1120). 7. Decrease the voltage increase value adjusted in the (P1310), (P1311) and (P1312) parameters. 8. Check if there is a member which prevents the functioning of the motor, and check if the motor is overloaded or not.
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ORIGINAL GUIDE
F0002
.F0003
FOO4
1. Check if the feeding voltage is between the limits mentioned on the tag plate. 2. Check if the DC-connection The feeding voltage is out voltage controller (P1240) is High voltage of the tolerance values. active or not and be sure that it is parameterized in the Regenerative load. correct manner. 3. Increase the motor revolution decrease duration (P1121). 1. Check if the feeding voltage is between the limits While the inverter is mentioned on the tag plate Low voltage functioning, the main supply 2. Check if there are shortis interrupted. duration failures or voltage drops in the feeding circuit. 1. While the equipment is functioning, check if the cooling fan is functioning. 2. Check if the pulse frequency is adjusted to the assumed value or not. High temperature in the inverter 3. The ambient temperature can be above the temperature value which is suitable for the inverter. 4. Check if there is clogging in the air inlet and outlet points.
F0005
Inverter I2T
F00010
Overheating in the motor PTC
F00011
F00021
929292101
Overheating in the motor
Grounding error
1. Inverter is over-loaded.
1.The motor may be overloaded. 2. Check the motor tag information. 3. Check the motor l2t warning level parameter. 4. Motor information is erroneous. 1.Grounding error at the outlet 2. IGBT failure.
1. Check if the load duty cycle is between the limits or not.
1. Check the motor tag information. 2. Consult the service department.
1.Check the grounding errors and correct them. 2. Change the fan.
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ORIGINAL GUIDE
F00030
Fan cooling is insufficient
Fan is faulty
1. The failure can only be masked in case the optional module (not BOP or AOP) is not connected. 2. Consult the service department.
1. Motor information presentation can not be realized.
F00041
Motor information presentation error
Alarm value = 0: no load Alarm value = 1: The current value reaches the limit level. Alarm value = 2: the defined stator resistance is smaller than 0.1 % or it is greater than 100 %.
Parameter EEPROM error
There is error in the reading or writing of the non-volatile parameter memory.
F00052
Contact group failure
The reading process of the contact group information is erroneous or the data is invalid.
F00060
Asic Timeout
F00051
F00071
F00072
During the time where the telegram is disabled, there is no data for the USS (BOP connection). During the time where the telegram is disabled, there is no data for the USS (COMMUNICATION connection)
Check if the motor is connected to the inverter or not.
1. Reset to the factory default values and define the parameters again. 2. Change the inverter. Change the inverter.
Confirm the failure. There is no answer during the TOT duration.
There is no answer during the TOT duration.
F00080
ADC lost input signal
F00085
External failure
F000101
Contact group overflow
F000221
PID Feedback is below the minimum value
PID Feedback P545 is below the minimum value
1. Change the P545 value. 2. Adjust feedback gain.
F000222
PID Feedback is above the maximum value
PID Feedback P544 is above the maximum value
1. Change the P544 value. 2. Adjust feedback gain.
939393101
ADC lost input signal External failure is triggered by means of the terminal inputs. Software error or processor failure
For failure triggering, make the terminal input passive. Apply automatic routine tests.
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ORIGINAL GUIDE
F000450
BIST Tests are unsuccessful
F000459
Failure warning
949494101
Error value 1 – Some of the tests of the power part are unsuccessful 2 – Some of the tests regarding the control panel are unsuccessful 4 – Some of the functional tests are unsuccessful 8 – Some of the IO module tests are unsuccessful. Only vector. 16 – Internal RAM did not realize the power feeding test.
1. The inverter may function, however, some functions may not be realized in a correct manner. 2. Change the inverter.
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ORIGINAL GUIDE PART 10 – HEALTH AND SAFETY OF THE OPERATOR 10.1- Rescue of the Squeezed Personnel If the personnel stand close to the clamps or if the personnel stand under the guided body during the downward movement of the guided body, the personnel may be squeezed. In this case, first of all, “the emergency stop” button should be pressed immediately, and the machine should be brought to the manual mode, and the clamp or the guided body should be lifted upwardly. In case of squeezing, there may be power interruption, in this case, you can rescue the squeezed personnel by lifting the guided body as in Figure 10-1 by means of the forklift. If there is crane or hoist in the machine operating area, a rope is connected to the middle region of the guided body, and afterwards the guided body is lifted and the rescued personnel can be rescued.
Figure 10-1
Attention! IN CASE OF AN INJURY, A DOCTOR SHOULD BE CALLED OR THE INJURED PERSON SHOULD BE BROUGHT TO A HOSPITAL URGENTLY.
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ORIGINAL GUIDE 10.2 The specifications of the lubricant used Blazing point ( °C ) and the method: 193° C closed reservoir Combustion temperature (°C): > 200 Fast burning limit: 1.5 – 6 The units formed as a result of burning: Essentially carbon-oxides, the organic compounds defined by water vapor Special burning / Dangerous explosions: On wide surface areas where air or oxygen is existing freely, the greasy wastes, papers may easily lead to combustion. These materials should be disposed after usage. Special extinguishing methods: The extinguishing stuff should come to the related region with equipment that provides breathing. Directly applying water to the stored containers is dangerous because of the boiling risk. Fire extinguishers: Foam, dry chemical powder, carbon dioxide. Appropriate materials / layers
: All of the general metals
Inappropriate materials / layers
: It may melt some plastics
Continuity
: Permanent
Reaction with water
: No
Dangerous reactions
: No
The materials that have to be kept away: The units that strongly oxidize other units The conditions that have to be kept away: High temperature Decomposition temperature ( °C )
: > 100
Dangerous decomposed products
: There is no composition of harmful decomposed products.
Storing temperature ( °C )
: 0 - 40
Storing precautions
: There is no special requirement. The factor that has to be kept away is the increasing temperature.
10.2.1 Transportation -
Technical precautions
-
Protection of the user: Provide appropriate ventilation in order to prevent the product being subject to the vapor or smoke thereof.
-
Avoid contact with used or dirty products. Keep the machine away from the flammable materials.
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ORIGINAL GUIDE -
Keep the machine away from comestibles.
-
Protection from fire and explosion: Empty tankers may comprise explosive gas and vapors. After the pouring of the product, the cloth, paper and other similar materials used in the collection of the product are flammable. These should not be accumulated, and after being used, they should be disposed of safely and immediately.
-
Precautions: Avoid the static electrification of the product, provide connection with the ground. Realize the machine adjustments so that the product does not pour on the hot pieces or the electrical equipment. Prevent leakage to the circuit operating under pressure. The liquid which comes out as a result of the leakage to this circuit is distributed by spraying and it is flammable. In this case, the lubricant vapor reaches the burning lower point in the concentration of 45 g/m3. During usage, nothing should be eaten, nothing should be drunk and cigarette should not be smoked
-
Transportation recommendations: Only reservoirs, gasket, pipe, etc resistant to hydro-carbon should be used.
10.2.2 Storing - .Technical precautions: Realize the necessary arrangements and take all the necessary measures in order to prevent the product to mix into the water and the soil. - Storing conditions . The appropriate method: Store in room temperature, keep away from water and humidity, keep away from flame sources. Keep the carriers closed when they are not used. . The factors that need to be avoided: Do not store the materials that have been subject to the product (cloth, paper, etc.) - Inappropriate products: It leads to a dangerous reaction with strong oxidants. - The packaging of the product . Recommended: Only reservoirs, gasket, pipe, etc resistant to hydro-carbon should be used. If possible keep it in its original carrier. Otherwise, place all the markings onto the new carrier according to the original carrier. 10.2.3 Identification of the dangers - Harmful for the human health: Under normal usage, it does not have any effect or danger. - Environmental effects: Do not pour this product into the environment. - Physical and chemical: Under normal usage, it does not have a special burning or explosion risk 10.2.4 The recommended first aid IN CASE OF A SERIOUS DISTURBANCE, A DOCTOR SHOULD BE CALLED OR THE PERSON SHOULD GO TO A MEDICAL ESTABLISHMENT. - Respiration: When a person is subject to the vapor or the spray of the product in dense form, this may lead to a light irritation in the throat of the person. The person should be taken outside, he/she should have a rest in a warm environment. - Contact with the skin: When the skin is subject to product spray in high pressure, the product may penetrate under the skin. The person who is subject to these conditions should be taken to the hospital even if there is no wound or visible sign on the skin. The clothes of the person which are subject to the product should be peeled off immediately. The part which is subject to the product should be washed with water and soap immediately and in a repeated manner.
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ORIGINAL GUIDE - Contact with the eye: With the eyes open, they should be washed with plenty of water for 15 minutes immediately. - Swallowing: There is a risk of vomiting and diarrhea. The person should not be vomited because of the risk of contact with the respiration system. Nothing should be drunk to the sick person. - Suctioning: If the product is thought to go inside the lungs because of any reason (for instance because of vomiting), the person should be immediately taken to the emergency service of the hospital. 10.2.5 Control of the usage / individual protection - Engineering precautions: The product should only be used in well ventilated places. When using the product in closed areas, be sure that there is no dense vapor effect in the air or put on / fix the recommended equipment. - Control parameters - The limit to be subject to: lubricant vapor: 10 mg/m 3 for 15 minutes lubricant vapor: 5 mg/m3 for 8 hours Individual protection equipment - Hand protection: Water-proof gloves which are resistant to hydro-carbon. The recommended material: rubber. - Eye protection: Eye-glasses against splashes. - Skin and the body: When necessary, mask for face protection, clothes resistant to hydro-carbon, safety boots (when carried by means of barrel) 10.2.6 Toxic information STRONG TOXIC / LOCAL EFFECTS - Respiration: It does not have a risk in normal usage. In respiration, according to the concentration of the vapor, it may lead to a light irritation in the upper part of the respiration system. - Contact with the skin: It does not have a risk in normal usage When the skin is subject to product spray in high pressure, the product may penetrate under the skin. The person who is subject to these conditions should be taken to the hospital even if there is no wound or visible sign on the skin. - Swallowing: If it is swallowed in small amounts, there is no risk. In case large amounts are swallowed, it may lead to an ache in the abdomen and to diarrhea. SENSITIVITY: Under the light of the known information, the product does not lead to sensitivity. CHRONIC AND LONG-TERM TOXIC EFFECT - Contact with the skin: In case of long-term or continuous contact with the clothes where the product is smeared, characteristic skin wounds (oily pimples) may form. 10.2.7 Annihilation information Annihilation of the wastes: Recycling and the re-using of the waste lubricants are essential. In cases where this is not possible, the waste lubricants should be annihilated without giving harm to human health and to environment. When the annihilation of the waste lubricates by burning is taken into consideration, the plants which took license according to Article 22 and Article 23 of the Regulations of Control of Dangerous Wastes will be used. Annihilation of the packages: It should be assessed under the wastes annihilation. Industrial waste EU number: 13-01-06 (hydraulic lubricants containing only mineral lubricant) Local responsibilities: dated 27.08.1995 and numbered 22387 Official Gazette, Regulations of Control of Dangerous Wastes
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ORIGINAL GUIDE PART 11 – DISMANTLING / DECOMMISSIONING THE MACHINE For the machines which have completed its operating life, in the decommissioning process; •
Bring the cutting table of the machine to the lowest position.
•
After completely emptying the hydraulic lubricant and cooling liquid in the machine, annihilate this lubricant and the cooling liquid according to the rules of the environment protection laws.
•
Unfix the bolts of the machine which fixes the machine to the ground.
•
The machine pieces can be classified as the following: o
Electronic wastes (sensors, drivers, circuit members…)
o
Steel recycle
o
Aluminum
o
Non-iron items (motor propellers, cable channels, plastic materials…)
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ORIGINAL GUIDE
PART 12 – FEEDBACK FORM Return:
Fax : + 90 224 242 75 80 – 242 93 73 e-mail :
[email protected] :
[email protected]
Catalogue version: Version 10.3 Date: ……………………………… Name: …………………… DCB-A 560
PLACE Company: ….……………………………………………………………………… Address: ….……………………………………………………………………… Authorized person: ….……………………………….. Unit/Position: .……………………… Telephone: ….……………………….. Email: ….…………………………………………. CONDITIONS Intermediate Heavy Working Conditions: Light Daily Working Duration:………………………. No Ambient Temperature: ………Current source in the vicinity (Welding machine): Yes Final Failure Date (if any):…………………… Unproblematic Working Duration: …………. FAILURE Indications:………………………………………………...…………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… ………………………………………………………………………………………… Things made:…………………………………………...………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… ……………………………………………………………………………… Comment(if there is any):………………………………………...…………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… ………………………………………… ………………………………………………………………………………………………………… 100100100101
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ORIGINAL GUIDE
TO WHOM:
DURMAZLAR MAKINA SAN. Ve TIC. A.S. Organize Sanayi Bölgesi 75. Yil Caddesi BURSA Fax : + 90 224 242 75 80 – 242 93 73 e-mail :
[email protected] [email protected]
DCB-A 560
Date: ………………………………
Catalogue version: Version 10.4 Name: ……………………
FROM WHOM? Company: ….……………………………………………………………………… Address: ….……………………………………………………………………… Authorized person: ….………………… Unit/Position: .……………………… Telephone: ….……………………….. Email: ….…………………………………………. Your comments and your evaluations are very important for us. Your positive/negative comments to us will provide us to improve our products and the descriptive documents in the direction of your requirements. Thank you for your cooperation…. Personally evaluate the machine and the user manual from 1 (very weak) to 5 (very good) in the below-mentioned topics: Performance Usage Safety Precautions Sufficiency of the guide Sale processes Transportation / Packaging After sales support
Comments (if any):……………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………….. …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………… …………………………………………………………………………………………
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